Case Study: Western Sydney Solar Team achieves composite weight reduction to 42kg and boosts efficiency with Altair

Optimizing a single-seat solar car for sustained endurance and total energy efficiency

The Western Sydney Solar Team, a student-run single-seat solar car team developing the “Unlimited 2.0,” faced the challenge of making the vehicle as aerodynamically efficient and lightweight as possible while meeting strict Challenger Class size and safety rules. They engaged Altair for composite engineering and simulation support to optimize the monocoque chassis, roll-hoop and motor housing within the existing geometry.

Altair delivered a three-phase composite optimization workflow—topology (shape) optimization, size optimization and ply-cleaning/stacking—under no-failure and stiffness constraints. The work cut composite mass from 80 kg to 42 kg (bringing composites to just 19% of total vehicle weight), produced a race-proven structure, and helped the Western Sydney Solar Team place 6th in the 2017 Bridgestone World Solar Challenge and go on to win the 2018 American Solar Challenge.

Western Sydney Solar Team

Max Mammone

Team Captain