Revolutionising Motor Performance: How Formero’s 3D Printed Motor Shrouds Power Monash Motorsport’s Success

Formero has been a proud sponsor of Monash Motorsport, providing us with world class 3D printing services for almost a decade. Formero prints M24’s custom motor shrouds, which protect critical wiring ensuring reliable functioning of the motors. Reliable motor power delivery and feedback ensure that M24’s motors are running as intended, so it is important to avoid these processes being interrupted. Motor Shrouds provide a solution by securing critical connections, and protecting them from external threats and forces.

Cable glands on motor shrouds clamp onto critical connections, providing strain relief and preventing damage to interior wiring, as macro forces from cable movements on the exterior of the shroud are suppressed. O-rings are printed on the inner shell of the shrouds, which when secured to our cooling jackets, waterproofs critical connections, subsequently improving reliability of motor power delivery and feedback wiring, while the exterior of the shrouds shell protects high voltage wires from external threats. Manufactured using Nylon PA-12, our motor shrouds withstand the high surface temperatures of our motors, while possessing the necessary strength levels to withstand heavy internal forces caused by moving parts within the powertrain. 

To print the various parts used in manufacturing M24, Formero uses Selective Laser Sintering (SLS). SLS printing uses high-powered lasers to bond powdered thermoplastic polymers in successive layers. This allows for greater accuracy and nullifies the need for support structures when printing. Usually, geometrically complex parts such as O-rings on the inner shell of the motor shrouds would require such structures to print accurately, but this need is surpassed using Formero’s high calibre SLS printing. 

Formero assists Monash Motorsport through all areas of the manufacturing process, such as coating prints upon completion with a clear lacquer, providing a glossy finish and improving the longevity of pieces by protecting the surface from environmental factors. Formero is in constant communication with our design and production team, assisting us how to best utilise their 3D printing services to optimise manufacturability. This helps us to innovate and find potential solutions in optimising our Motor Shroud design, such as optimising wall thickness, to maximise the level of reliability while minimising mass. 

Monash Motorsport are grateful for our ongoing partnership with Formero, as they continue to be an essential factor in our success.