What this project involved
Reduced suspension mass by 62%, from 110 lb to 41 lb, through structural optimization and lightweight component redesign while maintaining vehicle dynamics targets.
Designed components to meet geometry and handling targets including center-of-gravity height, KPI, caster, camber, and turning radius.
Designed welding fixtures to place 48 suspension mounting tabs on the chassis while controlling the geometric tolerances critical to suspension kinematics.
Performed SolidWorks FEA on 49 components using iso-clipping to guide lightweighting decisions and validate load paths.
Defined GD&T for machined suspension knuckles and hubs to ensure proper assembly and alignment.
Key takeaways
Mass reduction
A clear quantified result: 62% lower suspension mass without sacrificing performance targets.
Manufacturing realism
Went beyond CAD by creating welding fixtures and tolerancing schemes for actual chassis integration.
Analysis depth
Used FEA on 49 separate components to support lightweighting and validate structural behavior.
System-level design
Balanced mass reduction, suspension geometry targets, manufacturability, and assembly accuracy across the full suspension system.