Suspension of the car

Collaborating with the university, part of our team created a Formula Student car. One of the more challenging components showcasing the possibilities of generative modeling was the car's suspension.

Below is the process that was carried out.

At the beginning, we gathered all the requirements for the professions in which the vehicle with our suspension was to be used. We determined the operating conditions, load range, and design priorities.

We identified the capabilities of various manufacturing technologies and selected groups of materials that best met the requirements – both in terms of strength and weight optimization.

Step 1:

Analysis of requirements and selection of technology

We have thoroughly analyzed the geometric area where the suspension was to be applied. We defined all mounting points, spatial constraints, and relationships with other vehicle components.

We defined the loads and moments acting on the suspension structure to replicate the actual operating conditions.

Step 2:

Analysis of space and working conditions

We analyzed the generated models, comparing them in terms of stresses, displacements, safety factors, and mass. Based on this, we selected the best proposals for further development.

We created a full-size suspension prototype using 3D printing technology. This allowed us to verify the geometry in a real environment and check the cooperation with other components.

Step 4:

Analysis and prototypes

Based on previous analyses, we have prepared a complete representation of the assembly areas and geometric constraints in a CAD environment, which has become the basis for further simulations.

We have begun the simulation process using generative modeling techniques. The algorithms generated a series of possible construction variants, optimizing the geometry according to the specified criteria.

Step 3: 3D Modeling and Generative

The developed suspension meets all durability requirements while maintaining optimal weight and modern geometry. By using generative modeling, it was possible to shorten the design time and increase the innovation of the solution.

Final effect

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