Past Projects at Evology Manufacturing
Case Studies
Evology has tackled a wide range of complex manufacturing challenges. The case studies below show how our precision manufacturing and additive expertise solve real problems, walking through the planning, design iterations, and obstacles faced along the way.
Motorsport · DMLS
DMLS Motor Cooling Sleeve: How Illini Electric Motorsports Engineered Around Thermal Runaway
Illini Electric Motorsports designed an indirect DMLS aluminum cooling sleeve with a helical coolant path to keep their AMK motors below the derating cliff. The printed geometry cut convective thermal resistance in half and eliminated derating in endurance running.
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Motorsport · DMLS
DMLS Formula SAE Oil Pan: How UW-Platteville Reduced Weight by 37%
Pioneer Racing designed the PR26 structural dry-sump oil pan for DMLS from the start, cutting weight 37% versus PR25 and 57% versus the original machined concept, while holding a factor of safety above five. The lighter pan helped the team to its best Formula SAE Michigan finish in program history.
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Motorsport · DMLS
From CAD to Metal: FDF Raceshop’s Generatively Designed Handbrake & Clutch Pedal
Josiah Fallaise of FDF Raceshop designs his own performance parts with generative design, then needed a manufacturer who could print them in metal without cutting corners. Evology printed his hydraulic handbrake and BMW E46 clutch pedal in AlSi10Mg on an EOS M 290, North American made, structurally sound, and detailed enough to show every decision the software made.
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Automotive · Large-Format FDM
How Evology Helped Bring the EuroWise Cayenne Ultra to Life
When EuroWise needed custom fenders for their Cayenne Ultra and needed them fast, Evology moved from Digital Sheet Metal Forming to large-format FDM, printing a full set of carbon fiber layup molds in ASA on Stratasys Fortus 900 systems.
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Medical · Large-Format FDM
Large-Scale Additive Manufacturing for a Leader in Medical Equipment
When a leading medical equipment maker needed full-scale MRI patient tables and docks for a major trade show, traditional methods could not hit the size, complexity, or deadline. Evology delivered with large-format FDM.
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Motorsport · DMLS
Advancing Structural Innovation: Pioneer Racing FSAE's PR25 DMLS Oil Pan
For their 2024-2025 season, Pioneer Racing reimagined the PR25 powertrain as part of the chassis. The result was a DMLS oil pan that ties the engine to the rear plates, enables a dry sump system, and could not be machined conventionally.
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Motorsport · DMLS
Reinventing Performance: Evology & MSOE Baja's Lightweight Rear Knuckles
MSOE's Raider Racing Baja team redesigned their rear suspension knuckle with DMLS. The new part cut weight, improved structural integrity, and sharpened suspension performance, all on a tight pre-race timeline.
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Every project here started with a hard problem and a tight timeline. Send us your files and our team will scope the right process, recommend a material, and get you a quote.