Formula E differs from Formula 1 in that the chassis is standardised, with each team competing with the same specification, but the development of other parts including the electric motor, inverter, gearbox, rear suspension and software can be specially designed by each team. This marks the design and development of the powertrain as one of the deciding factors in the battle to finish first in both the driver’s and constructor’s championship.

Polar Technology are the chosen supplier for a number of key components for selected constructors within Formula E and are helping to enable their technologies to maximise high-performance in an industry where every tenth of a second counts.

Utilising their expertise in advanced composite materials, as well as their strong background in motorsport and their ethos of focusing on technology that helps to build a sustainable future, Polar Technology are well-equipped to continue to expand their offering for Formula E in the coming years.

The products that are currently showcased on this season’s cars include:

Drive Shafts

As market leaders in the development of lightweight, energy-efficient transmission components, Polar Technology are able to design bespoke drive shaft assemblies, which are a crucial element of the powertrain of Formula E cars.

Their patented mechanical interface removes reliance on adhesives and can subsequently deliver high speeds and high torques with extreme durability, ensuring significant weight savings, increased safety and enhanced performance.

For more information on our transmission shafts, click here.

Rotor and Stator Sleeves

Electric motors are another vital part of the powertrain, with them serving the same purpose as the combustion engine in a F1 car, in terms of converting energy (supplied by the battery) into mechanical power.

This process provides challenges, with the motors required to rotate at high speeds and therefore generating high centrifugal force on the motor’s magnets. Polar Technology’s solution is optimised carbon-fibre sleeves, which work to retain the magnets and minimise the current losses. They have perfected a press-fitting technique that fit the sleeves to the motors directly, which enables a higher retention pressure.

The mating part to the rotor sleeve is the stator sleeves, which serve the purpose of maintaining the cooling medium of the stator pack. The combination of these parts offers the minimal air gap and offset between the rotor magnets and the stator, thus enabling optimum performance from the motor.

For more information on our sleeve solutions, click here.

Gearbox Housings

Gearbox housings within Formula E are the main structural element of the rear of the car, and are required to be lightweight, with strict regulations to follow. Polar Technology are well-placed to be the chosen supplier for this component, with an in-house moulded composites department, a precision metallic machining department and the equipment and experience to machine large complex components such as the entire gearbox housing.

They have developed a core manufacturing technique that allows the assembly to be produced with a single cavity tool, as opposed to assembling multiple smaller components together. Metallic elements can also be incorporated during the manufacturing process, with Polar possessing the capability to machine any required inserts in-house as well as machining and inspecting the final assembly.

Meanwhile, utilising Finite Element Analysis (FEA) in the design stage allowed Polar Technology to identify areas that needed strengthening, and where further weight reductions could be made, to ensure an optimised, turnkey solution is delivered to our customers.

Polar Technology are proud to be a part of the innovation occurring within Formula E, which is breaking new boundaries and pioneering future mobility in the electric vehicle industry.

To speak to our team about any queries you may have on any of the products mentioned above, visit our designated Contact page.