Key 3D printed EV parts for Energica platforms
CRP Technology, together with CRP Meccanica, played a pivotal role as a technological partner in the R&D and testing of all Energica electric motorcycles – developing functional 3D printed EV parts and assemblies using Windform materials.
The following overview highlights a selection of 3D printed structural, electrical, and aerodynamic components created for the Legacy and Experia platforms, as well as for the Ego Corsa racing motorcycles – demonstrating how Windform thermoplastics support both rapid development and real-world performance validation without design compromises.
Integrated Engineering Value
Engineering activities developed and coordinated within CRP’s multidisciplinary teams, supporting system integration and validation beyond manufacturing execution
Mass centralization and ride dynamics used to define EV packaging architecture
Load-based functional prototyping accelerating validation cycles
Integration aligned with Energica’s proprietary VCU/BMS architecture and diagnostic standards
Structured mileage testing and feedback-driven performance optimization
Energica Experia. High-Voltage innovation on two wheels
CRP Technology supported the development of Experia, Europe’s first electric green tourer and the most recent platform engineered by Energica, from the early R&D phases – producing functional parts in Windform composites for structural reinforcement, aerodynamic optimization, and electrical insulation.
Component | Material | Phase | Features / Impact |
|---|---|---|---|
Rear grab handle | Windform SP, painted | Prototype, pre-series | Tested in homologation tensile test (1700 – 1900 N); accelerated functional validation |
Front nose | Windform XT 2.0, painted | Prototype, pre-series | Aerodynamic geometry; mold geometry validated, tooling risks avoided |
Side panel (fairings) | Windform XT 2.0, vapor smoothed | Prototype, pre-series | Enhanced aerodynamics and surface finish; supported efficiency testing |
Battery pack insulation plates | Windform FR1, vapor smoothed | Prototype, pre-series, production | Flame-retardant (UL 94 V-0, FAR 25.853); ensured battery safety through structural and thermal stability |
Fast charging plug | Windform LX 3.0 | Prototype, pre-series | High dielectric constant (~4); dimensional stability; enabled design validation without redesign |
Legacy Platform. Functional end-use 3D printed EV parts in Windform
CRP Technology supplied direct-to-use components for Energica’s earlier motorcycle models, confirming the long-term reliability and performance of Windform composite materials in operational conditions.
For the electric motorcycles of the Legacy platform, CRP Technology 3D printed several structural and functional parts on behalf of Energica. Most of these components were mounted on production vehicles and deployed in operational environments.
Below is a selection of key examples:
Component | Material | Phase | Features / Impact |
|---|---|---|---|
Chain slider and sprocket cover | Windform XT 2.0 | Prototype, pre-series, production | Abrasion and vibration-resistant; protected drivetrain, reduced wear |
Water pump support | Windform TPU | Prototype, pre-series, production | Flexible and shock-absorbing; simplified design and reduced part count |
Rear grill | Windform XT 2.0 | Prototype, pre-series, production | Durable and thermally stable; enhanced cooling performance; ensured protection of powertrain elements |
Motor terminal cover | Windform LX 3.0 | Prototype, pre-series, production | Stable and insulating; improved safety and component lifespan |
MotoE Ego Corsa. 3D printed EV parts in racing conditions
Launched in 2019, the MotoE™ World Cup marked a historic shift in two-wheeled motorsport toward electric mobility and sustainability. Energica was selected by Dorna as the single manufacturer for the championship from 2019 to 2022.
For the FIM Enel MotoE™ World Cup, CRP Technology supported Energica in the development of high-performance components tested under extreme racing conditions.
The combined expertise of CRP Technology and CRP Meccanica in advanced manufacturing, high-performance composites, and precision CNC machining was instrumental in transforming the Ego Corsa into a competitive, high-voltage racing platform.
Component | Material | Features / Impact |
|---|---|---|
Connectivity control unit and battery isolation indicator | Windform LX 3.0 | Dielectric housing (~ε4); thermally stable; reduced electrical failure rate (up to 25%) |
Chain slider and transponder holder | Windform XT 2.0 | Lightweight yet robust; resistant to vibration, abrasion, and fatigue |
Air intake | Windform XT 2.0 | Strength and airflow optimization; improved thermal management and battery performance |
From a Designer's perspective. Functional 3D printed prototypes without compromise
When designing complex components for electric vehicles, engineers need materials that not only perform like final production parts, but also integrate seamlessly into fast-paced development workflows.
CRP Technology’s Windform composites meet these needs -enabling functional prototyping, direct testing, and design freedom without compromise.
No redesign
CAD-ready for production, no adaptation required
Final-Part Performance
Test and validate like a production component
CNC Finishable
Compatible with post-machining and precision finishing
Fast Turnaround & Aligned Support
No rework, just streamlined development