McGill Formula Electric team integrates AON3D Hylo printer for high-performance battery component production. The McGill University student team utilized the Montreal-based AON3D Hylo, an AI-powered FDM/FFF system, to manufacture a battery cell and PCB holder for their high-voltage accumulator. The component was printed using ULTEM 9085, a high-performance thermoplastic featuring a tensile strength of 94 MPa, a flexural strength of 129 MPa, and a heat deflection temperature of 169 degrees Celsius, meeting UL94 V-0 flame retardancy requirements. Zaven Renaud, powertrain manager at McGill Formula Electric, confirmed the system enabled rapid iteration and part consolidation that exceeded the capabilities of standard desktop 3D printers.

This deployment highlights the increasing reliance on industrial-grade extrusion systems within collegiate motorsports to meet stringent safety and performance standards. While desktop FDM/FFF printers are common in academic settings, the requirement for high-temperature materials like ULTEM 9085 necessitates industrial hardware capable of active chamber heating and precise thermal management. AON3D competes in the high-temperature polymer segment against established players like Stratasys and Intamsys, positioning its open-material platform as a flexible alternative for research and low-volume production. The ability to process high-performance engineering resins allows teams to bridge the gap between prototyping and end-use functional parts in resource-constrained environments.

For engineering teams, the primary value of this implementation lies in the validation of DfAM principles for safety-critical electrical housings. Users should prioritize the selection of materials with verified thermal and flame-retardant properties when moving from hobbyist equipment to industrial-grade AM systems. Future success for AON3D in this sector depends on maintaining its open-material ecosystem while ensuring consistent mechanical performance for demanding automotive applications.