Francesco Monte
Upright's design using additive manufacturing for a Formula Student car.
Rel. Andrea Tonoli. Politecnico di Torino, Master of science program in Automotive Engineering, 2025
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Abstract
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
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