UPBRacing
Traditional design goes on a diet!
The client
For the 2021 edition of the FormulaStudent event, UPB racing team from Paderborn university Germany were keen to try something new. Entering the new electric vehicle category posed an exciting challenge, a challenge which would allow them to rethink the race car from the ground up. In order to capitalise on this shift from ICE to EV, they would seek the aid of Additive Center in partnership with Hexagons powerful MSC simulation and generative design software to push the limits of innovation and hopefully win the race!
The challenge
Opting for 4 independent electric motors mounted directly onto the wheels not only allowed the team to simplify the drive chain compared to traditional ICE, but also equipped them with 4-wheel drive, hopefully providing them with an edge over the competition! However, they were now faced with the complex challenge of squeezing an electric motor and planetary gear box into the already complex wheel carrier.
Utilising MSC Apex generative design under the guidance of Additive Center allowed the team to quickly generate different iterations to determine the most optimal design. For critical high-performance and costly components it is important to be methodical. Employing Simufact Additive from Hexagon, the students were able to simulate the additive manufactured part and check for manufacturing-induced stresses, distortions cracks and hot spots caused by the printing process. This allowed them to be confident the design would
perform as intended straight from the printer.
Final result
The advantages
Reduces material
Organic, monolithic design, preventing unnecessary use of material
Weight reduction
The weight of the part went down with 47%
Easy assembly
Assembling this part is much simpler.
Assured design
The design was first time right due to simulations and printed as one piece
Find out how it is assembled in the video below:
Additive Center takes great pride in being a founding member of AMcubator. This ecosystem enables us to collaborate with other top-tier companies to achieve optimal results. What distinguishes AMcubator is our steadfast dedication to delivering tangible business value. From housing leading 3D printing companies to providing cutting-edge equipment in our pilot factory, AMcubator offers a distinctive platform for collaboration and innovation. Our objective? To streamline your AM journey, enhance processes, and ultimately propel scalable applications to market success. Interested in discovering how AMcubator can add value? Click here to learn more.
The following companies contributed to this specific project:
Utilising MSC Apex generative design under the guidance of Additive Center allowed the team to quickly generate different iterations to determine the most optimal design.
Employing Simufact Additive from Hexagon, the students were able to simulate the additive manufactured part and check for manufacturing-induced stresses, distortions cracks and hot spots caused by the printing process.
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