Investigation of generative design for powder bed fusion technology in case of Formula Student race car components using Ti6Al4V alloy

Abstract

In case of the racing car of the Formula Student competition, there was a need to use more modern solutions in the development of metallic parts. In the context of the joint research on the applicability of metal additive manufacturing, a methodology has been developed that will enable more efficient use of metallic parts in the future, from component selection across the generative design and 3D printing process steps to the validation of the results. As a further result of the research, we applied the new methodology to the 4 rocker components in the suspension of the racing car chassis, and as a result, we achieved a weight reduction of 40 % per component and three times higher load capacity. The built-in rocker's in-service testing and final approval took place on the ZalaZone proving ground.