Case Study: KU e-Racing achieves lighter, faster race cars and 40% shorter production time with Stratasys 3D printing

Ku E-racing Meets Racing Challenges With 3D Printed Production Parts

KU e-Racing, Kingston University’s electric race car team, faced challenges with heavy metal components, overheating air intakes and frequent part failures as they developed successive race cars. To meet the demands of motor-racing they turned to Stratasys for additive manufacturing solutions, using Stratasys 3D printing (including production systems such as the Fortus 400mc and materials like ABSplus, ULTEM 9085 and PC‑ABS) to prototype and produce durable, lightweight parts.

Stratasys’ 3D printing enabled KU e‑Racing to replace metal parts with production-grade plastic components—printing shutdown mounts, switch housings, exhaust fan housings and redesigned air-intake parts—that withstand shock, heat and vibration while allowing more complex geometries. The Stratasys solution reduced overall vehicle weight and improved airflow and speed, eliminated costly manufacturing inaccuracies, and cut production time by about 40% compared with traditional methods.

KU e-Racing

Aldus von der Burg

Team Leader