Uprights and brake calipers by Formula Student 2021

IMPACT CASE II - Chalmers Formula Student and EOS, Finland (2021)

Researchers: Bharat Mehta (Chalmers), Eero Virtanen (EOS, Finland)
Students: Robin Kristiansson (Uprights) and Anton Hansson (calipers) (CFS’2021)
Industry partner: EOS, Finland
Parts: Uprights and brake calipers
Material: AlF357 or AlSi10Mg
Additive process used: Parts printed on EOS M290
Benefits: Uprights ~70% weight reduction, Simpler and smaller part, brake calipers ~33% weight reduction, improved packaging, single body

  • The printed parts are Uprights and brake calipers, part of the set of components apply to the suspension sub-assembly of the car.

  • The suspension is a critical area as it has very high loading with cyclic loads in all directions imaginable! Thus, the possibility to design these components using advanced generative design softwares such as Inventor etc. shows that AM has a lot of potential.

  • Weight savings as high as 70% has been shown on large components, while retaining the same performance in terms of loads with an added factor of safety. All these components are built in AlSi10Mg which is a famous commercial Aluminium alloy. It was chosen as they are easier to print, readily available and thus simulation work on these parts could be done with greater confidence.

  • All parts were printed using LB-PBF as the technology for printing.

brake calipers
Uprights and brake calipers printed with aluminum alloys

Page manager Published: Wed 31 Aug 2022.