Case Study: Gurit achieves nearly 50% composite weight reduction (80kg to 42kg) with Altair

Optimizing a Solar Car for Endurance and Energy Efficiency

Gurit engaged Altair to help optimize the composite structures for the single-seat solar car Unlimited 2.0, facing the challenge of minimizing mass while meeting strict Challenger Class size limits, load cases and driver-safety g‑force requirements. Gurit needed to refine the monocoque chassis, bulkhead, motor housing and design a compliant roll‑hoop within an existing geometry to achieve maximum aerodynamic and energy efficiency for long endurance racing.

Altair delivered a three‑phase solution using its composite‑optimisation, topology‑optimisation and FEA tools to perform shape, size and ply optimisation, translating topology results into manufacturable ply layouts and exporting 3D ply geometry for construction. The Altair‑enabled process reduced composite weight from 80 kg to 42 kg (just 19% of total vehicle weight) and supported strong race performance—6th in the 2017 Bridgestone World Solar Challenge and a win at the 2018 American Solar Challenge.

Gurit

Max Mammone

Team Captain