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Electric Race Car & DWS 3D Printed Molds

Dynamis Case Study | 10 Therma DM570 Resin 3D-Printed Molds for Autoclave Lamination

Published on

November 7, 2025

As part of the international Formula Student competition, the Dynamis PRC team from Politecnico di Milano set out to develop a high-performance single-seater electric race car, introducing significant design innovations over previous years.

To manufacture carbon fiber aerodynamic components with complex geometries, the team collaborated with DWS Systems, a company specialized in advanced 3D printing.

The partnership began during MECSPE 2023, where the potential of 3D printed molds to overcome the limitations of traditional manufacturing became clear.
This case study highlights key engineering decisions, the development of high-temperature resin molds, and the technical results—focusing on process efficiency and on-track performance gains.

The car project

Dynamis PRC is the racing team of Politecnico di Milano, participating in the Formula Student international championship. Composed entirely of students from multiple engineering disciplines, the team designs and builds a race-ready single-seater evaluated on engineering design, track performance, and cost-effectiveness.

For the 2025 edition, the focus was on introducing advanced aerodynamic solutions never used before, aiming to significantly increase the vehicle’s performance.

Aerodynamic Challenges and Material Selection

The new aerodynamic elements required for the project featured complex 3D geometries, essential for optimizing the car’s efficiency.

Among the components produced were:

- Front wing elements, including outer sections connecting the center flaps to the footplate, characterized by multi-axis curvature.
- Floor-mounted vortex generators, designed to increase underbody suction and enhance total downforce.

To meet the requirements of shape, weight, precision and repeatability, it was necessary to rethink the entire mold production process.

Choosing 3D Printing: Manufacturing of carbon fiber molds

The choice to adopt 3D printing for mold production stemmed from the need for greater design freedom and faster turnaround times compared to conventional CNC milling.

In collaboration with the R&D department of DWS, the aerodynamic team designed and produced 10 high-temperature resin molds using Therma DM570, a material engineered to withstand autoclave curing cycles—typically used for injection molding, but here applied successfully to carbon fiber prepreg parts.

Thanks to this technology, it was possible to:

Rapid production of intricate geometries
Elimination of CNC machining
Accelerate the entire vehicle construction process, increasing the time available for testing and fine-tuning

“DWS resin printing technology is unique within the additive manufacturing space. Unlike other printable materials, Therma DM570 withstands pressurized autoclave curing, ensuring structural integrity of the part.”

Pietro Torri

Sporting Director, Dynamis 2024-2025

Quantifiable Results

Thanks to the adoption of DWS technology, the following advantages were achieved:

Mold production time: less than 4 days
Capability to handle complex extremely geometries
Excellent surface quality, with a significant reduction in the finishing phase
No CNC milling required
Compatibility with full autoclave cycles without deformation

Quotes from the interview

“An additional advantage of the molds made by DWS is the resin used: the low porosity of the material minimizes the post-printing processing time, drastically reducing the preparation phase compared to other materials traditionally used for this type of application.”

Paolo Da Ros

Head of Aerodynamics, Dynamis 2025

Learnings and advice for the industry

The use of high-temperature resin 3D molds proves particularly advantageous in contexts where high performance is required:
• Rapid development times
• Small-batch production with cost-efficiency comparable to traditional manufacturing methods
• Custom and complex geometries

The choice of mold type therefore strongly depends on the production context, the specific goals of the project, and, above all, the number of parts to be produced.

Comparative table: technologies for mold manufacturing

3D Print (Resin)

Cost:Low–Medium

Production Time:2–4 days*

Complex Geometries:Excellent (high design freedom)

Expected Duration:Medium (depends on material and usage)

* Including post-processing stages (cleaning, UV curing, thermal curing, treatment with release agent), the maximum time frame can be up to 4 days.

Metal (Aluminum/Steel)

Cost:High

Production Time:2–4 weeks

Complex Geometries:Limited (by CNC process)

Expected Duration:Very high (thousands of cycles)

Composite (Glass/Carbon)

Cost:Medium

Production Time:1–2 weeks

Complex Geometries:Good

Expected Duration:Medium (tens–hundreds of cycles)

CNC-Machined Resin

Cost:Medium

Production Time:1–2 weeks

Complex Geometries:Limited (depending on processing)

Expected Duration:Low (prototypes/small run)

Legend:
• Costs: Low | Medium | High
• Time: Fast | Medium
• Geometries: Limited | Good/Excellent
• Durability: Mold lifespan before deterioration

Final Thoughts

The results obtained with the Therma DM570 material confirm its potential not only for autoclave applications, but also for sectors where high thermal resistance, dimensional accuracy, and rapid production are required.

DWS confirms its position as a strategic technology partner for the development of advanced solutions in the world of composites and additive manufacturing.

The Therma DM570 material demonstrated excellent performance in this specific application, withstanding a temperature of 135°C and a pressure of 6 bar during a 2-hour autoclave cycle.

The carbon fiber parts were easily released from the mold thanks to the material’s low surface porosity, which ensured a smooth finish and high aesthetic quality on the final part. This property enabled immediate release, successfully overcoming one of the most critical stages of the process—where other technologies have struggled or even failed.

It is therefore the ideal material for producing molds for autoclave-cured prepreg carbon fiber.

If you’d like to test the DWS solution for autoclave molding, contact us by filling out the form.

We will be happy to support you in achieving your goals!

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Material and 3D Printer in this Case Study

Therma DM570

High-performance material specifically engineered to withstand high temperatures and pressures while maintaining a high degree of dimensional precision and accuracy.

Discover more

XPRO SL

Industrial applications for big parts. 50 cm Z axis.