Upright's design using additive manufacturing for a Formula Student car.

This thesis focuses on the design of a Formula Student car upright optimized for additive manufacturing. The design process begins by analyzing the previous iteration, which was manufactured using conventional production methods, highlighting its advantages and limitations. This initial evaluation serves as the foundation for determining whether additive manufacturing presents a viable alternative, considering the project’s specific targets and constraints. Once the manufacturing approach is selected, the design objectives are defined, with a primary focus on achieving an optimal balance of stiffness, reliability, and weight. To accurately determine the forces acting on the component, various load cases are introduced, representing critical vehicle dynamics such as cornering, braking, acceleration, and combined scenarios. For each load case, input loads and contact patch coordinates are identified, enabling the calculation of forces through a dedicated physical model. Additionally, geometric constraints are established to accommodate the surrounding components within the wheel assembly. With the design targets and loading conditions set, a custom finite element model (FEM) is developed to evaluate the component's performance. Prior to detailed FEM analysis, a topology optimization study is conducted to identify stress-concentrated regions and eliminate unnecessary material, thereby minimizing weight while maintaining structural integrity. Special consideration is given to design parameters that mitigate overhangs and other limitations inherent to additive manufacturing. Throughout the process, industry best practices for additive manufacturing are applied to ensure an efficient and manufacturable design. Following the structural assessment, FEM simulations are carried out to verify stiffness and reliability. Finally, a fatigue analysis is performed to estimate the component’s lifespan and establish a maximum operating time. This study aims to demonstrate the feasibility of additive manufacturing for high-performance automotive components, offering insights into its potential benefits and limitations.