Case Study: TU Graz achieves 29.4% lighter brake pedal with SLM Solutions

Material reduction with high-strength, lightweight material and topology optimization

TU Graz, through its Racing Team and Institute of Production Engineering, needed a lighter, stronger brake pedal for its Formula Student race car. The team wanted to move beyond a traditionally milled part and use additive manufacturing to achieve topology-optimized geometry, improved ergonomics, and the weight savings required in motorsports. SLM Solutions’ SLM® technology and Additive.Designer® software were used for the project.

SLM Solutions helped TU Graz redesign and 3D-print the brake pedal in Ti6Al4V on an SLM®280, enabling both topology optimization and functional integration. The final part weighed 108 g instead of 153 g, cutting weight by 29.4% while keeping stiffness within an acceptable range, and also integrated the brake fluid reservoir directly into the pedal.

TU Graz