Case Study: University of Paderborn achieves 47% lighter FormulaStudent wheel carrier with Hexagon MSC Apex Generative Design

From load simulation via generative design to manufacturing and verification – optimisation of a wheel carrier for FormulaStudent with MSC Software

The University of Paderborn's FormulaStudent team faced the challenge of optimizing a wheel carrier to drastically reduce weight for their race car. Their previous method, which used a 5-axis milling machine, was extremely inefficient, wasting 97% of the raw material. They required a faster, more effective design process and turned to Hexagon, utilizing its MSC Apex Generative Design software to find a solution.

Hexagon's solution leveraged MSC Apex Generative Design and Simufact Additive to create a new, generative design for the wheel carrier optimized for additive manufacturing. This resulted in a 47% weight reduction, bringing the component down to 265g. Furthermore, Hexagon's software significantly reduced manufacturing distortions and enabled a process that was completed in days instead of weeks, allowing the team to validate the part's integrity and ensure a right-first-time production.

University of Paderborn