---
title: "3D printing unlocks innovation for McGill’s Formula Electric team"
url: https://www.voxelmatters.com/3d-printing-unlocks-innovation-for-mcgills-formula-electric-team/
date: 2026-03-31
modified: 2026-03-31
lang: en
author: "Tess Boissonneault"
description: "Every year, student teams from around the world put their efforts towards building the fastest electric race cars and test their designs at the Formula SAE Electric competition. The tradition,..."
categories:
  - "3D Printing Processes"
  - "Electric Vehicles"
  - "Research & Education"
  - "Sports Equipment"
tags:
  - "insights"
image: https://www.voxelmatters.com/wp-content/uploads/2026/03/mcgill-formula-electric-1-640x426.jpeg
word_count: 539
---

# 3D printing unlocks innovation for McGill’s Formula Electric team

Every year, student teams from around the world put their efforts towards building the fastest electric race cars and test their designs at the Formula SAE Electric competition. The tradition, born out of the decades-old combustion Formula SAE races, is meant to inspire engineering students and get them to put their knowledge to work in a tangible, innovative, and more sustainable way. At McGill University, based in Montreal, Canada, a team of undergraduate students is working diligently to design and build an electric race car while conforming with a strict budget and production guidelines.

It should come as no surprise that the McGill Formula Electric (MFE) team has therefore embraced the use of 3D printing in its development and production. The technology, which enables agile, low-volume production, as well as design freedom, has become increasingly important in motorsports—even at the [Formula 1 level](https://www.voxelmatters.com/exploring-additive-manufacturing-in-the-2026-formula-1-technical-regulations/). For MFE, 3D printing has been an essential tool, enabling it to rapidly iterate new designs, make changes on the fly, and find innovative solutions for its vehicle.

For example, 3D printing was indispensable in the development and production of a battery cell and PCB holder. The component, used in the race car's high-voltage accumulator, plays an important role, securing pouch battery cells and supporting the PCB responsible for monitoring and controlling the battery module. To fulfill this function safely, the holder needs to be made from a flame retardant material, as well as offer excellent thermal stability and electrical insulation.

[![3D printing unlocks innovation for McGill’s Formula Electric team](https://www.voxelmatters.com/wp-content/uploads/2026/03/mcgill-formula-electric-2.jpeg)](https://www.voxelmatters.com/wp-content/uploads/2026/03/mcgill-formula-electric-2.jpeg)MFE team at Formula SAE Electric 2025 in Brooklyn, NY (Photo: McGill Formula Electric)

Not having the resources or time to develop and manufacture the part using conventional production methods, the MFE team turned to industrial-grade AM. Specifically, the team leveraged the [AON3D Hylo 3D printer](https://www.voxelmatters.com/aon3d-reveals-new-hylo-3d-printer-and-basis-software/), an AI-powered extrusion machine engineered for high-performance materials like PEEK and ULTEM. [AON3D](https://www.3dprintingbusiness.directory/company/aon3d/), also based in Montreal, specializes in [open material industrial 3D printers for high-temperature materials](https://www.voxelmatters.com/aon3d-kevin-han-interview/).

By using AON3D Hylo, the MFE team was able to reap the benefits of rapid iteration and validation enabled by AM. It was also able to use a suitable end-use material, ULTEM 9085, to test and ultimately manufacture the part. The thermoplastic, which is characterized by a tensile strength of 94 MPa, flexural strength of 129 MPa, a heat deflection temperature of 169°C, and UL94 V-0 flame retardancy, was the ideal fit for the battery holder application.

In this case, 3D printing and ULTEM 9085 enabled the McGill Formula Electric team to iterate and validate the battery holder component in a cost and time efficient manner. The team was also able to leverage DfAM benefits, specifically through part consolidation. "AON3D Hylo allowed our team to produce race-ready parts quickly and affordably, with mechanical, thermal, and fire-safety properties far beyond what we could achieve with desktop 3D printers," commented Zaven Renaud, powertrain manager on the MFE team.

The battery holder is just an example of how MFE and other Formula SAE teams are exploiting the advantages of 3D printing. Even within Montreal, other higher educational institutions are leveraging the technology to pursue motorsport innovation. At the *École de Technologie Supérieure* (ETS), for instance, the Formula SAE team used [metal AM in the production of its MANIC-23 electric race car](https://www.voxelmatters.com/montreal-based-formula-sae-team-enlists-renishaw-to-3d-print-critical-metal-parts/).