Formero: Protective, Proven and Precise Motor Shroud Printing
Formero continues to provide Monash Motorsport with world class 3D printing services for M25’s custom cooling jackets and motor shrouds. Together they protect critical wiring, provide cooling to the motors and ensure that our new custom cobalt motors can deliver reliable power, all while fulfilling this year's mass focused design requirement.
Formero is Australia's largest and most advanced 3D printing service provider, providing fast, cost effective and detailed prints with a vast selection of materials, catering to any industry. For our cooling jackets and motor shrouds, Formero utilises Selective Laser Sintering (SLS). SLS technology features high-powered lasers that bond powdered thermoplastic polymers in successive layers, allowing for greater accuracy and nullifying the need for support structures when printing. Usually, geometrically complex parts, such as o-ring grooves on the inner shell of the motor shrouds, would require these supports to be removed, however, using Formero’s high calibre SLS printing removes this requirement and provides smoother surface finishes and overall higher quality prints.
Furthermore, Formero provides z-bonding for Monash Motorsport SLS parts, which improves the surface finish and importantly waterproofing of the part. This is crucial for our cooling jacket which, with z-bonding, can now resist up to 120°C without leaks, providing us with a super lightweight and effective solution.
The motor shroud assembly serves as a critical protective and structural component within M25’s powertrain. Integrated cable glands mechanically secure and seal electrical components, providing strain relief to prevent conductor fatigue and insulation wear from vibration or movement. This design isolates interior wiring from macro forces generated by cable motion outside the shroud, ensuring long-term reliability of the motor’s high-voltage and signal connections.
Each shroud is manufactured from Nylon PA-12, a high-performance thermoplastic, used for its combination of thermal resistance, tensile strength and dimensional stability. This material withstands the elevated surface temperatures produced by the cobalt motors while retaining its mechanical integrity under internals stressed induced by rotating and reciprocating components within the powertrain. The result is a lightweight yet robust solution that balances mechanical performance with this year’s mass optimisation targets.
Grooves are printed into the inner surface of the shroud, allowing o-rings to be used as compression seals when mounted to the motor. This interface prevents moisture ingress and provides an effective barrier against dust and debris - critical to ensuring the high voltage connections remain continuous in all weather conditions. The outer shell of the shroud functions as a mechanical shield, protecting critical components from impact, abrasion, and exposure to high-velocity debris during operation.
Formero continues to be a key technical partner for Monash Motorsport, working alongside our engineers to refine and validate the design of M25 motor shrouds and cooling jackets. Their ongoing communication with our team members allow us to adapt our components for efficient additive manufacturing, ensuring print quality and mechanical performance are maintained from prototype through to final assembly. Together, we ensure that our components are manufactured to the highest standard, aligning with the team’s design and performance targets.
Thank you Formero for your continued support and your pivotal role in Monash Motorsport's success.