Programmable Foam® in Formula E
In Formula E, cockpit space is extremely limited, and even small impacts can put a driver’s hands at risk. During a crash, the hands tend to hit the same carbon structure inside the cockpit, and the hardness of that surface has historically caused fractures. To improve hand protection, the series introduced specially designed 3D-printed Programmable Foam® pads that act as shock absorbers.
A fast track from idea to finished parts
Shock absorption is one of the key characteristics of Programmable Foam®, which makes our material a strong match for this unique safety challenge. The request came with urgency: all cars were required to add the pads, and the season start was approaching.
Because we have research and development resources within our 3D print service, we could quickly move into rapid trial-and-error development. When we receive a design with a specific function, we create a tailored printing strategy to achieve the optimal internal structure. In this case, we combined insights on where the hands typically make contact, how little space was available, and how to tune the material to absorb impact effectively.
When plan A fails, precision matters even more
The initial concept explored another type of integration, but it was not possible to implement it in time. With the deadline approaching, our team restructured tasks to support the new plan: pads mounted directly onto the carbon structure inside the cockpit.
We produced and delivered the full order within three weeks, and the pads were installed across the Formula E grid. Some teams have even customized them in their car colors.
Programmable Foam® for shock absorption
It is not only motorsport that benefits from strong impact-absorbing properties. Active wheelchair users experience the same advantages in their seating aids, where Programmable Foam® also helps reduce pressure, improve comfort, and support long-term durability. You can read more about the technology here:
Bring us your toughest challenges
Our 3D print service is continuously exploring new applications for the Programmable Foam® platform. Any product that relies on traditional foam today may benefit from a more modern, controllable, and sustainable technology.
If you want to explore what is possible — whether for seating aids, insoles, or functional parts like the Formula E case — then reach out. Together, we can develop solutions that improve existing products and unlock new opportunities.
