{"id":124310,"date":"2025-09-30T12:21:04","date_gmt":"2025-09-30T10:21:04","guid":{"rendered":"https:\/\/xometry.pro\/stories\/euss-motorsport-electric-car\/"},"modified":"2026-02-18T22:41:30","modified_gmt":"2026-02-18T21:41:30","slug":"euss-motorsport-electric-car","status":"publish","type":"stories","link":"https:\/\/xometry.pro\/en-eu\/stories\/euss-motorsport-electric-car\/","title":{"rendered":"Building the EM-05: Our Journey to EUSS Motorsport\u2019s Most Innovative Electric Race Car"},"content":{"rendered":"\n

At EUSS Motorsport, I serve as Head of Vehicle Dynamics, where I design the assemblies that complement the chassis, components essential for the car\u2019s performance on track. My fascination with mechanics led me to study engineering, and discovering that my university had a Formula Student team made joining an obvious choice. It gave me the chance to put theory into practice, learn far beyond the classroom, and work alongside people who share the same passion for innovation.<\/p>\n\n\n

From Combustion to Electric<\/strong><\/h2>\n\n\n

Since its founding in 2017 at the Escola Universit\u00e0ria Salesiana de Sarri\u00e0 (EUSS)<\/a> in Barcelona, EUSS Motorsport has designed and built Formula Student single-seaters\u2014small-scale Formula 1 cars. After developing three combustion-engine cars, we made a decisive change: transitioning to electric.<\/p>\n\n\n

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Work on the EM-04 single-seater in the workshop<\/p>\n <\/div>\r\n <\/div>\r\n \r\n

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EUSS Motorsport team<\/p>\n <\/div>\r\n <\/div>\r\n \r\n

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EUSS Motorsport team<\/p>\n <\/div>\r\n <\/div>\r\n \r\n

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EUSS Motorsport team<\/p>\n <\/div>\r\n <\/div>\r\n \r\n

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EUSS Motorsport team<\/p>\n <\/div>\r\n <\/div>\r\n \r\n <\/div>\r\n <\/div>\r\n

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This move wasn\u2019t just about keeping up with the times. It was about aligning with the industry\u2019s shift toward sustainable mobility, challenging ourselves, and staying ahead of competition rules. Formula Student Germany<\/a>, the most prestigious event, will soon no longer accept combustion-powered cars\u2014so switching early gave us an advantage.<\/p>\n\n\n\n

Our first steps into electric racing came with the EM-04 car, which we presented at Formula Student Spain 2024<\/a>. That experience gave us valuable insights into high-voltage systems, integration challenges, and safety standards, and it became the foundation on which the EM-05 was built.<\/p>\n\n\n

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Still, the transition has been the biggest challenge in our history. Electric propulsion required us to rethink the vehicle\u2019s entire architecture. High-voltage systems, strict safety rules, and new approaches to dynamics meant nothing could be reused from our combustion era. For us in the Dynamics department, this meant not only designing our assemblies but also ensuring they worked seamlessly with electronics, powertrain, and aerodynamics. Every decision had ripple effects, and mistakes often taught us faster than successes.<\/p>\n\n\n

The Process Behind Our Most Advanced Car Yet: The EM-05<\/strong><\/h2>\n\n\n

Designing and building a Formula Student car starts with setting our main goals\u2014whether that\u2019s reducing weight, improving lap times, or implementing new technologies. Once the objectives are clear, each department begins the conceptual design phase, brainstorming ideas to reach those targets.<\/p>\n\n\n\n

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CAD model of the EM-05 electric race car<\/figcaption><\/figure>\n\n\n\n

From there, we move to detailed design in CAD, run simulations, and check that all the parts fit and work together. Communication between departments is crucial, because a single change in one system can affect many others. Once the design is finalized, we move into manufacturing, assembly, and finally on-track testing, where real-world performance often reveals details we need to adjust. Seeing the car progress from sketches to reality and then watching it perform on track is, without doubt, the most rewarding part of the process.<\/p>\n\n\n\n

The EM-05, our second electric single-seater, is the result of everything we learned from its predecessor, the EM-04. By applying lessons from the past season and competitions, we\u2019ve consolidated a motivated, cohesive team ready to push further.<\/p>\n\n\n\n

The EM-05 incorporates substantial improvements compared to the EM-04:<\/p>\n\n\n\n