Formula Student Team Uses EOS P 396 for 3D Printed Airflow in the Battery Housing 

DHBW Engineering Stuttgart | Success Story

  • Design allows for the fast servicing of safety-relevant parts

  • Reduction of the component weight by 80 % to just 77 g

  • Well over twice the cooling performance when compared to the previous year's car

"EOS' expert knowledge and technology have really helped us to get our electric powered race car eSleek14 on the track and recording great times. The advantages of Additive Manufacturing are very convincing: lightweight components, the fast realization of ideas, and all this possible for extremely small part quantities. The available materials mean that safety is never compromised. Thanks to the instruction received from EOS we were able to get the maximum out of the process – and prove ourselves out on the track."

David Köhler | Assistant Head of Battery Development for the race team 2013/2014

Serious Power: Cooling System for Formula Student Race Car Produced With Additive Manufacturing

The eSleek14, belonging to the DHBW Engineering Stuttgart team, has two electric motors, each with 60 hp. The electricity that feeds this speed machine comes from batteries fixed laterally inside the vehicle. The construction of the air cooling system was supported by EOS in its role as Additive Manufacturing expert.

In the development of the battery container it was possible to realize not only the cooling channels between the individual modules, but also a cooling duct that directed the air back outside in the most efficient way at the end of the container.  In order to satisfy the strict specifications for component weight, the team chose the lightweight fine polyamide PA 2200 for the construction. This material is characterized by its high rigidity and good thermo conductivity – perfect characteristics for motorsports applications.

The air duct was produced using the EOS P 396, the laser beam melting the powdered material layer by layer to form the final component.The next step would be to successfully integrate the components into the vehicle. The weight also met the desired criteria: the cooling duct component weighs just 77 g.

Cooling Unit

"We decided to have the cooling duct additively manufactured and, thanks to EOS' technology, we had complete freedom of design. With such small quantities, injection-moulding didn't make sense, and we would anyway, have had to make changes to the construction design."

David Köhler | Assistant Head of Battery Development for the race team 2013/2014

The Results at a Glance

  • -80 % Weight reduction
  • 100 % Performance improvement

EOS Success Stories

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Rennteam Uni Stuttgart race car | © Rennteam Uni Stuttgart

Producing Topology-Optimized Steering Stub Axle

Success Story | Formula Student

In the construction the student engineers employed for the first time an additive manufacturing (AM) process and the car went on to win the title.

GreenTeam Uni Stuttgart race car | © GreenTeam Uni Stuttgart

Additive Manufacturing for the Formula Student

Success Story | GreenTeam Uni Stuttgart

Design of a flow optimized, oil resistant and flameproof distribution unit for the cooling system of an electric racing car.

Additive Manufacturing

in Motorsports