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2024 · Engineering

Topology Optimized Upright – Formula Student TU Berlin

Development and optimization of a topology-optimized wheel carrier for the TU Berlin Formula Student racing car. Through additive manufacturing, significant weight reduction was achieved while improving structural integrity.

Topology Optimized Upright – Formula Student TU BerlinEngineering — 2024

Project overview

During the 23/24 season, I developed the front uprights of our car. In addition to a machined component, I also designed an additively manufactured variant, showcasing innovation in materials and production techniques.

First development of a conventionally manufactured model
Fig. 01First development of a conventionally manufactured model
Final optimized design with significant weight reduction
Fig. 02Final optimized design with significant weight reduction
Upright assembly with bearing, brake disc and caliper
Fig. 03Upright assembly with bearing, brake disc and caliper
FT24 – the TU Berlin Formula Student car
Fig. 04FT24 – the TU Berlin Formula Student car
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