Industry: Motorsports · Automotive · R&D
Technology: Metal Additive Manufacturing (Laser Powder Bed Fusion)
Material: Aluminum Alloy
Machine Used: EP-M250Pro
Overview: Compact, Efficient Cooling for High-Performance Electric Motors
As demand grows for more compact and efficient thermal management systems, conventional manufacturing techniques are proving increasingly limited. In motorsports especially, lightweighting, high power density, and optimized thermal control are critical.
In this case study, we explore how Germany’s Formula Student racing team “E.Stall”, from Esslingen University of Applied Sciences, leveraged metal 3D printing to reimagine a cooling water jacket—a crucial component used to manage the temperature of electric motors under race conditions.
Challenge: Overheating Motors and Water Leakage Risks
The E.Stall team has been a respected contender in the international Formula Student Germany (FSG) competition. After experiencing repeated cooling system failures due to water leakage from plastic cooling jackets in previous seasons, the team sought a more durable and high-performance solution.
Their original jacket design—made from high-temperature-resistant plastic and split into two bonded shells—proved problematic under racing conditions, often resulting in leaks that jeopardized motor reliability and overall race performance.
Solution: Redesign with Additive Manufacturing and EP-M250Pro
To address these limitations, the team partnered with EPLUS3D to explore an additive manufacturing approach using aluminum alloy and the EP-M250Pro metal 3D printer. This strategy allowed for an integrated, leak-proof, and weight-optimized design, unattainable with traditional methods.
Key Benefits:
Single-Piece Design: Eliminated the need for bonding/sealing, drastically reducing leak risk
Integrated Cooling Channels: Complex internal pathways embedded within thin-walled structures
Material Upgrade: High thermal conductivity aluminum improves heat dissipation
Lightweight: Reduced wall thickness and optimized geometry led to size and weight reduction
Design Freedom: Complex shapes and simulations iterated quickly, thanks to additive capabilities
Tech Specs (Final Component)
- Inner Diameter: 94 mm
- Outer Diameter: 112 mm
- Height: 126 mm
The EP-M250Pro, featuring precision laser powder bed fusion technology, enabled the team to achieve high surface quality, dimensional accuracy, and excellent mechanical strength, ideal for demanding motorsport applications.
Simulation-Led Design Optimization
Using fluid simulation software, the E.Stall team iterated on several internal geometries to maximize cooling efficiency. The final version of the 3D printed water jacket managed to reduce wall thickness, decrease the overall component diameter, and maintain consistent coolant flow for both motors during high-load operation.
This digital design-to-manufacturing loop—empowered by metal 3D printing—allowed the team to rapidly prototype, test, and finalize a cooling solution that is now a key performance component in their Formula Student electric vehicle.
Results: Performance Gains and Production Advantages
- Enhanced Cooling Efficiency → Reliable thermal control during full-throttle race conditions
- No Leaks → Durable, monolithic part eliminates failure-prone joints
- Rapid Prototyping → Accelerated design iterations via simulation and AM integration
- Weight & Size Reduction → Compact and lightweight, critical for competitive motorsport
“With Eplus3D’s support and the EP-M250Pro’s precision, we were able to reduce the water jacket’s wall thickness and integrate cooling channels—something unimaginable with traditional manufacturing,”
— E.Stall Racing Team
Conclusion: Pushing the Limits of Motorsport Design with 3D Printing
This project illustrates how metal additive manufacturing is revolutionizing thermal management in electric vehicle applications. By unlocking advanced geometries, improved material use, and rapid development cycles, 3D printing has become a powerful enabler of innovation in high-performance racing.
