Case Study: Auburn University achieves 50% monocoque weight reduction and improved chassis stiffness with Altair HyperWorks

Auburn University applies HyperWorks to Optimize the Design of Composite Suspension Components and Monocoque for a SAE Formula Student Racecar

Auburn University’s Formula SAE team faced the challenge of optimizing composite suspension components and a carbon-fiber monocoque to reduce mass and increase stiffness while meeting SAE rules and tight build deadlines. To meet this challenge they used Altair’s HyperWorks CAE suite—including HyperMesh for meshing, OptiStruct for topology and composite optimization, and HyperView for post-processing—to drive a simulation-led design process.

Using Altair HyperWorks the team built detailed FE models, assigned composite and aluminum properties, ran a three-step OptiStruct optimization, and validated manufacturable designs in HyperView. The Altair-enabled workflow produced dramatic gains: the optimized monocoque achieved a 50% mass reduction versus the previous all-aluminum baseline while maintaining stiffness, the final chassis weighed 51 lbs with torsional stiffness of 4,000 ft‑lb/deg, and development time was shortened while the students’ composite design skills improved.

Auburn University

Drew Campbell

Lead Monocoque Design Engineer