The monocoque is the backbone of our Formula SAE car - a full carbon-fibre chassis that provides the strength, stiffness, and safety essential structure for high performance. The complexity of the chassis requires every hatch, cut-out, and mounting feature to hold its shape throughout the curing process, where extreme pressure and temperature can easily cause distortion. To achieve this, Monash Motorsport relies on highly specialised tooling known as monocoque plugs.

*Monocoque Plugs - Printed by Formero using Selective Laser Sintering (SLS) Printing*

For M25, we partnered with Formero, a long-time supporter of Monash Motorsport and a leader in advanced additive manufacturing. Formero’s expertise in Selective Laser Sintering (SLS) printing allows us to produce custom plugs that make the composite layup process faster, more accurate, and more reliable.

Formero has been working with Monash Motorsport for close to a decade, providing advanced manufacturing solutions across multiple systems. Their ability to deliver high-quality components with rapid turnaround times makes them an invaluable partner. One of the main reasons we choose to work with Formero is the consistency and precision of their printing processes. Unlike traditional methods that require sanding or machining draft angles, Formero’s SLS printing builds these features directly into the part. This not only eliminates post-processing requirements but also ensures that every plug fits perfectly in the carbon-fibre panels, straight out of their printer.

The monocoque plugs produced by Formero are manufactured in PA-12 nylon, a material specifically suited for the demands of composite manufacturing. It combines high strength and stiffness with the ability to withstand the curing cycles of heat and pressure without deforming. The plugs are designed directly from our CAD models and printed to exact specifications, meaning they can integrate seamlessly into the monocoque structure during curing.

These plugs are used to hold the shape of critical features such as the steering rack mounts, accumulator cooling cutouts, loom pass-throughs, and larger access hatches. By occupying these spaces during the curing process, the plugs prevent the carbon fibre and core from collapsing or warping into the openings, ensuring that once the plugs are removed, the cutouts retain their precise geometry.

The introduction of Formero’s plugs has had a significant impact on the way we manufacture our chassis. In previous years, we relied on metal tooling, such as angled aluminium pieces, which often bent or warped under the curing conditions, compromising the accuracy of the final part. By contrast, Formero’s SLS-printed plugs are dense, rigid, and resistant to warping, maintaining their integrity under even the harshest conditions.

The ability to 3D print plugs allows the team to be flexible during the design process. Instead of designing cutouts to suit existing molds, the plugs can be designed to suit whatever geometry is required. This flexibility has made it possible to pursue more advanced design solutions for the car without being constrained by tooling limitations. The elimination of additional sanding, machining, and draft-angle preparation has streamlined the entire manufacturing process, saving a lot of critical time that can be used to manufacture and refine other parts..

*Selective Laser Sintering (SLS) Printing at Formero*

Working with Formero has been a smooth and collaborative process. Their team is highly responsive to design changes, and the efficiency of their production means that we can integrate parts quickly and confidently. For Monash Motorsport, the support from Formero extends well beyond individual components. Their contribution helps us focus more on innovation and performance, knowing that our manufacturing processes are backed by high-quality, reliable tooling.

We are proud to continue our partnership with Formero, whose expertise and support allows us to push the boundaries of what is possible in engineering.

Precision in Every Layer: Formero’s 3D-Printed Monocoque Plugs

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