How the FORZE Racing Team Uses Rapid Prototyping 3D Printing to Build a Hydrogen Race Car

The FORZE racing team runs on hydrogen and tight deadlines. This student-led crew of 45 volunteers builds hydrogen-powered Le Mans prototypes. Rapid prototyping 3D printing with the MakerBot Method XL keeps their development cycle measured in hours, not weeks. Here is how one university team turned a desktop printer into a real edge.

The Challenge: Building a Hydrogen Race Car on a Student Budget

FORZE competes in the Supercar Challenge across the Benelux region with the Forze 9. This hydrogen-powered Le Mans prototype runs on clean energy, and every part on the car reflects the team's focus on performance.

Hydrogen powertrains need custom parts with tight tolerances. The design cycle never stops. CNC machining would have meant long wait times and high costs. For a student team with limited funds and no access to outside shops, those delays would have stopped the project cold.

The team needed a faster way to build test parts: one with low cost, fast output, and enough strength for real-world use.

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The Solution: MakerBot Method XL

FORZE added the MakerBot Method XL to their workshop. Its 305 x 305 x 320 mm build volume, dual-extruder system, and heated chamber handle full-size parts in one run.

Three materials cover the team's needs. ABS handles most prints thanks to its strength and ease of use. ABS Carbon Fibre goes into structural parts where stiffness matters. RapidRinse, a water-soluble support, dissolves in warm water. No manual support removal needed, even on complex shapes.

Parts once built over weeks now print in hours. The team checks fit, tests clearances, and spots design issues before they affect the full assembly.

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The Results: Faster Cycles, Stronger Teamwork

What began as one printer and some curiosity has grown across multiple departments. 3D printing and prototyping now runs through daily work, with members sharing slicing tips, material settings, and finishing methods through an internal channel.

Ernst Paardekooper, Mechanical Engineer, describes the learning culture: "We've learned a lot along the way. 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\u2014like material settings\u2014can be tricky to get right at first."

The team also set up an internal admin role to manage UltiMaker's Digital Factory platform and fix material issues. This keeps the printers running and the team focused on building.

Koen Vogels, Chief Chassis, sees the output growing: "We're already printing a lot more now, and as we continue to iterate, we're likely to increase our use of 3D printing. 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."

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Skills Beyond the Track

For FORZE members, 3D printing delivers more than race car parts. It builds skills in design loops, material choices, and digital production. These are the same skills hiring managers in automotive, aerospace, and consumer goods look for in new graduates.

Australian universities and TAFE programmes with similar projects see the same gains. Students who prototype, test, and refine with 3D printing enter the workforce with hands-on experience. For more on this, see our guide to the top 5 benefits of 3D printing in higher education.

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Frequently Asked Questions: Rapid Prototyping 3D Printing

What is rapid prototyping with 3D printing?

Rapid prototyping with 3D printing means producing physical parts from a CAD file to check fit, form, and function before locking in production tooling. A printer like the Method XL turns a digital design into a testable part in hours, giving teams fast feedback without outside help.

What materials does the Method XL support?

The Method XL prints with ABS, ABS Carbon Fibre, ABS-R, Nylon, Nylon Carbon Fibre, and support materials including RapidRinse (water-soluble) and SR-30. Its heated chamber (up to 110 \u00b0C) and heated build plate cut warping across the full 305 x 305 x 320 mm build area.

How does 3D printing benefit engineering students?

3D printing for students gives hands-on practice in design, material selection, and testing. Instead of staying in CAD, students build real parts, test them, and improve their work. Teams like FORZE show how this leads straight to job-ready skills in fields driven by fast product development.

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Ready to bring rapid prototyping into your university or student lab? View the MakerBot Method XL or request a quote to talk through your setup. Browse the full MakerBot range.

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3D Printer 3D Printers 3D Printing Education ABS ABS CF Carbon Fibre Printing Hydrogen Racing MakerBot MakerBot Method XL Rapid Prototyping RapidRinse Student Engineering