Method series

FORZE Racing Team’s 3D Printing Integration in Hydrogen-Powered Prototype Development

User Profile Image

Bennie Sham

February 2, 2025

The Forze racing team is run by 45 student volunteers focused on developing the Forze 9, a hydrogen-powered Le Mans prototype car. Competing in the Supercar Challenge in the Benelux, the team is committed to advancing clean energy in motorsport, specifically focusing on hydrogen-powered vehicles. With limited resources and tight deadlines, the team has embraced 3D printing as a crucial technology to fast-track their prototyping, manufacturing, and iterative design processes.

The integration of 3D printing has allowed the team to quickly create and refine parts, optimize their designs, and adapt to the unique challenges of creating a hydrogen-powered racing vehicle. This approach not only speeds up the engineering cycle but also enables the team to experiment with designs.

FORZE DSC00777

Engineering a champion

Being a student-run team, Forze faces numerous challenges, including limited budgets and access to external manufacturing services. Traditional methods, such as CNC machining, would have meant long lead times and high costs. Given the complexity of developing a hydrogen-powered vehicle, rapid prototyping was essential to test, iterate, and refine key parts on the fly, particularly to ensure proper fit and functionality.

The Method XL 3D printer has become central to the Forze team’s workflow. With its dual-extruder system, large 305 x 305 x 320 mm build volume, and user-friendly features, it allows the team to print prototypes quickly and efficiently, while ensuring high-quality and reliable parts for their vehicle’s critical systems. The printer has improved integration between different components of the vehicle, allowing the team to quickly test parts, check the fit, and even identify potential issues before they affect the larger assembly.

FORZE DSC00897

The printer’s ability to produce parts using materials like ABS, carbon fiber, and Rapid Rinse has been especially valuable. It has enabled the team to prototype parts that are both lightweight and strong, essential to extreme environments.

The team primarily uses ABS for prototyping due to its durability and ease of use, while carbon fiber is used for high-strength applications like structural parts. The Rapid Rinse support material, which dissolves easily and quickly in warm water, has been ideal for more complex parts that require intricate geometries without support structures. While the team has PLA available, it’s typically reserved for smaller, non-critical parts.

FORZE DSC00726
FORZE DSC00737

3D printing has drastically reduced development timelines for prototyping. What would have taken weeks through traditional manufacturing processes now takes hours, allowing the team to get real-time feedback and make design improvements much faster.

FORZE DSC00783

3D Printing's impact on team collaboration

The adoption of 3D printing has led to a shift in how the team works together. What started as an initial curiosity about prototyping with a single printer has evolved into widespread adoption across multiple departments. The team has quickly learned how to leverage the technology for more efficient design iteration and production, making it a key part of their daily operations.

While the printer is easy to use, the team also dedicated time to learning about slicing, material properties, and post-processing techniques. The team shares knowledge internally, with more experienced members offering support to those new to 3D printing. There’s even an internal “administrator” role for managing the Digital Factory platform and troubleshooting more complex issues, such as material-specific challenges.

“We’ve learned a lot along the way,” said Ernst Paardekooper, Mechanical Engineer. “We have a channel for 3D printing, and someone with more experience in slicing materials helps others when they get stuck. Even though the printer is intuitive, some things—like material settings—can be tricky to get right at first.”

For students like those in the Forze team, working with 3D printing provides invaluable hands-on experience that can directly benefit their future careers. The ability to rapidly prototype, iterate on designs, and troubleshoot issues equips students with practical, industry-relevant skills that are highly sought after by employers. These experiences prepare students for roles in industries like automotive, aerospace, and consumer goods, where rapid prototyping and product development cycles are key.

FORZE DSC00692

Plans for future expansion

As the Forze team’s work continues to evolve, they anticipate increasing their use of 3D printing. The printer’s capability to handle larger builds and complex designs has opened up opportunities for even more parts to be 3D printed, including structural components and custom fixtures.

“We’re already printing a lot more now, and as we continue to iterate, we’re likely to increase our use of 3D printing,” said Koen Vogels, Chief Chassis. “Having a printer that’s reliable and easy to use has already given us an edge. It allows us to try new ideas quickly and efficiently.”

Competitive advantage

3D printing has become an essential tool for their hydrogen-powered car’s development, while providing essential skills that will prepare them for future careers.

Having access to 3D printing in an academic setting provides students with the opportunity to work with advanced manufacturing techniques that are increasingly common in industry. Many engineers are now expected to know how to utilize 3D printing in product development, and teams like Forze offer students a chance to build these skills in a real-world setting, even before graduation.

FORZE DSC00695