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Motorsport Upright Suspensions

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Manufacturing Technology Centre
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Motorsport Upright Suspensions
Benefit: Increased Component Complexity, Weight Saving
Main Forming Process: Additive Manufacturing
End Use Sector: Automotive
Material: Titanium


The formula student car, Oxford Brookes racing team in collaboration partnership with The Manufacturing Technology Centre (MTC) demonstrated the capability to manufacture complex automotive parts using Additive Manufacturing (AM), Electron Beam Melting (EBM) process.

The Challenge:

  • To achieve part weight saving with better improved mechanical properties though topology optimisation redesign
  • Formula car students were looking to develop expertise in design and manufacture of AM
  • To manufacture four upright suspension parts using Ti6Al4V material and gain in- depth knowledge of AM possibilities

The Outcome:

  • A demonstration of how AM can be used to manufacture complex geometries
  • Weight saving by >30% through topology optimisation
  • Reduced lead time from design changes to manufacture of parts in comparison to existing conventional methods

The Solution:

  • The parts were manufactured using the EBM process, providing a solution via non-conventional manufacturing
  • Validation of the part quality through Non-Destructive Testing (NDT) using X-Ray Computed Tomography (XCT) and Bluelight technology for quality and dimensional measurements
  • Benefits to the student and engineers:
    • Increased knowledge of design and validation of highly complex and efficient geometries for AM production, to support existing aerospace AM capability
    • Increased knowledge of the student and engineers in AM process, including understanding the role, requirements and influence of topology optimisation and post-processing

Component Specification

Density (g/cm3): 4.4
Tensile Strength (MPa): 900
Yield Strength (MPa): 875
Elongation (% strain): 15
Hardness (HRA): 325

The information contained in these case studies is provided by third parties and although EPMA does its best to ensure the case studies are accurate it is not liable for any mistakes or wrong information

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