Case Study: UPBracing achieves a lighter, high-performance electric race car with Hexagon Generative Design

Integrating gear and motor into an electric race car’s wheel carrier

UPBracing, a student team from Paderborn University, faced the challenge of designing a new, highly stiff wheel carrier for their electric Formula Student race car. The new design needed to integrate an electric motor and a planetary gear into a very compact space while managing significantly higher loads than their previous internal combustion vehicle. They turned to vendor Hexagon and its MSC Apex Generative Design software to engineer a solution.

Using Hexagon's generative design approach, the team created multiple optimised design alternatives, which were then simulated with Hexagon’s Simufact Additive to test for manufacturing issues. This process resulted in a wheel carrier that was both robust and lightweight, contributing to the overall success of their PX 421 E race car. The car achieved a total weight of only 212 kg and an acceleration of 0-100 kph in 3.6 seconds, leading to a fourth-place finish at the Formula Student competition.

UPBracing

Florian Bäumer

Chief Technology Officer