FIM Enel MotoE World Cup: 3D Printing to Develop New Ego Corsa Electric Motorcycle

Italy-based Energica is a subsidiary of CRP Group, a motorsports pioneer also headquartered in Italy and creator of the advanced Windform laser sintering materials, which were used to 3D print Energica’s Ego electric motorcycle.

At this year’s CES, visitors to CRP Group’s booth had a chance to see the Ego’s 3D printed seats and dashboards for themselves, as Energica prepared to enter pre-series production for the motorcycle.

We also learned that Dorna had chosen Energica, which has a range of three motorcycles, as the sole manufacturer for the FIM Enel MotoE World Cup, which will take place in 2019, and that a finely tuned version of the Ego will be used by teams racing in the electric motorcycle competition.

“The FIM Moto-e World Cup is a new and exciting project for Dorna, and it makes us very proud to announce Energica will be the supplier in this new venture,” Dorna Sports CEO Carmelo Ezpeleta said. “We believe in excellence, quality and performance and we cannot think of a better collaborator with whom to launch the FIM Moto-e World Cup. Energica are an industry-leading and innovative company and we look forward to the incredible spectacle of electric-powered racing together.”

Just like with the original Ego, CRP Group will use its Windform composite 3D printing materials and SLS, DMLS, and High Precision CNC Machining techniques to help Energica develop the new bike for the World Cup.

The recent announcement stating that CRP Group is officially Energica’s technological partner for MotoE also revealed more information about the company’s new electric racebike – the Ego Corsa.

“Our history comes from racing, Energica is part of the CRP Group, since 1970 a pioneer in the world of international motorsports and a hub of excellence for its state-of- the-art technologies,” said Livia Cevolini, CEO of Energica Motor Company S.p.A. and Marketing Director CRP Group. “Our passion in the field of innovative technologies has never faded. We are ready to sign a new chapter in motorsport history along with the CRP Group, Dorna, Enel, FIM and Michelin.”

The Ego Corsa is a more tuned-up version of Energica’s original Ego sportbike, and as previously mentioned, will be put to work on the race track by teams at the FIM Enel MotoE World Cup.

The heart of the Ego Corsa, which accelerates from 0 to 60 mph in 3 seconds, is its synchronous oil-cooled motor with permanent magnets, and it can reach a top speed of 155 mph. The electric racebike is regulated by a ride-by-wire system, which means riders can control acceleration and deceleration based on the engine braking, or regenerative torque, without having to rely on a clutch or gearbox.

“The FIM is very happy to support the development of new technologies, of which the new FIM Moto-e World Cup is an example,” said Fédération Internationale de Motocyclisme (FIM – International Motorcycling Federation) President Vito Ippolito. “Energica is proving itself to be a reliable and expert leader in this sector and with the highly qualified support of Dorna we are sure that we are taking the road to success.”

Energica has received three patents covering important components of the Ego Corsa: the latest generation eABS, which can limit the maximum regenerative torque in case of slippery conditions; the Vehicle Control Unit (VCU), which monitors and manages the battery, inverter, charger, and ABS; and the supply unit, which contains the rechargeable batteries in a specially designed battery case, complete with aluminum cooling plate so they don’t overheat.

CRP Group, along with its CRP Meccanica and CRP Technology families, has worked in the Formula 1 world for over 45 years. Energica, the first Italian manufacturer of high-performance electric motorcycles, was developed between 2008 and 2009, when the CRP Group created its all-electric eCRP racing bike. CRP Group used its technical expertise, 3D printing technology, and experience to create a new concept of motorcycle racing, and thus its Energica subsidiary was born.

[Image: Energica]

“The attitude towards innovation, the ability to evolve it and the ‘look beyond’ disposition are our milestones,” said Cevolini. “In a short time Energica has opened a new chapter in the history of Italian Motor Valley, creating a new field within the automotive market: the high-performance electric motorcycle segment.”

CRP Group has called on its experience in the F1 and aerospace industries, and its 3D printing know-how, to support Energica as it worked to continue developing electric vehicle technology, and create its line of premium, street-legal electric motorcycles, which also includes the Eva.

Energica’s R&D team is committed to the new Ego Corsa, and is currently working on track specifications and drivability. CRP Group will be involved in many phases of its development, as the electric motorcycle will share many of the same features with the original Ego production bike it’s modeled after…potentially even some more 3D printed components.

A testing demo program for the new Ego Corsa will be held during the MotoGP World Championship.

Italy’s former three-time world MotoGP champion Loris Capirossi told The Times of India about the Ego Corsa, “I really loved it, it’s an incredible feeling, you can now even hear the sound of your knee touching the track.

“The bike is quite heavy but because the weight is quite low (because of the electric batteries) it’s agile and builds power in a linear way.”

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