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Challenge
Build a reliable, lightweight
axle-pivot with high rigidity,
in the shortest possible time.
Solution
Production of a topology-
optimized steering stub axle
using EOS technology.
Results
• Optimized: perfect form
	 and contouring for a
	 reduced weight by 35%
	 and an increased rigidity
	 by 20%
• Speedy: significant
	 shortage in development
	 and production time
• Safety: reliable on the
	track
Facts
Customer Case Study Automotive
Easing to Victory – The Rennteam Uni Stuttgart Wins
the Formula Student Germany with EOS support
In the construction the student engineers employed for the first time an additive manufacturing process
and the car went on to win the title. (Source: Rennteam Uni Stuttgart).
Short profile
The Rennteam Uni Stuttgart is
an independent club composed
of highly motivated students
from a broad range of fields.
It takes part in the Formula
Student racing series, a
competition for young
engineers, across Europe,
as well as being involved
in other international com-
petitions.
Address
Rennteam Uni Stuttgart
Pfaffenwaldring 12
70569 Stuttgart (Germany)
www.rennteam-stuttgart.de
The greater the force in play, the greater the resulting counter-force – a relatively basic rule of
physics. Such rules are particularly relevant in motorsports, where the stresses placed on the utilized
materials are extreme. Taking the circuit at high speeds exposes both driver and car to the effects of
such forces. The young constructors of the Rennteam Uni Stuttgart are constantly striving to optimize
the construction process and the use of materials.
More and more the sport demands that not only should the driver pilot the car ever quicker around
the track but, within the principles of the Formula Student Germany series, he should do it safely. In
the construction of the successful 2012 model the student engineers employed for the first time an
additive manufacturing process in the building of the knuckles - and the car went on to win the title.
EOS supported the team through its victorious Formula Student Germany season.
Challenge
The knuckle – also called the axle-
pivot – connects the wheel axle with
the wishbones and the track rod via
a bearing. The braking system is
then likewise fixed to it. The part
conducts all the forces and momen-
tum absorbed from the wheels to
the wishbones and the tie rod, and
on to the vehicle chassis itself. On
the one hand, every constructor of
an axle-pivot has the task of
developing a part with the highest
possible stability – otherwise the
safety of the vehicle as a whole
would be undermined. Besides a
fracture, part deformation can also
have serious consequences, as the
kinematic design and, as a result,
the drivability, would be negatively
impacted.
On the other hand, the wheel mounts
cannot, for a number of reasons,
weigh too much. Every additional
gramme increases lap times, and
the wheel mounts belong to the
so-called unsprung mass of a vehicle.
The less there is of this mass, the
better the suspension and shock
absorption will function. A low
wheel-mount weight allows the car
to sit better on the track – impor-
tant for fast laps and safe racing.
As a consequence, constructors are
faced with the tricky task of finding
the perfect balance between rigidity
and weight.
Young engineers choose additive manufacturing
to tap the full potential of the part
Thanks to additive
manufacturing, the
weight of the knuckles
was reduced by
660 grammes in all.
Numbers that were
translated into faster
lap times and reduced
fuel consumption
(Source: Rennteam
Uni Stuttgart).
Previous production technologies
offered the Stuttgart race team too
little room to maneuver in the
search for this perfect balance. “The
wheel mount we‘d been using over
the last few years had already
achieved a good balance between
weight and rigidity, but we were
sure we could improve on it,”
explains Yannick Löw from the
Rennteam Uni Stuttgart. “We
produced the part using the classic
precision casting process. This, of
course, led to limitations in freedom
of form, which meant that the
part‘s potential could never be fully
realized. Even back then we‘d
decided that for the 2012 season
we‘d investigate new, innovative
ways of manufacturing the steering
stub axle.” It didn‘t take long for
the team to decide upon the path
to take: The EOS-technology.
Solution
As early as the conceptual design
phase, the engineers utilized the
CAD software from EOS partners
Within Technologies Ltd. Within is a
young company, whose programmers
wrote their software specifically
for the additive manufacturing
process. The program makes possible
the optimization of latticed
micro-structures of variable densities
following examples found in nature.
Thanks to this tool the constructors
were able to match the part
perfectly to the structural require-
ments. In this way, they were able
to give the knuckle precisely the
required physical properties – light-
weight plus rigidity.
“By the simplified, so called, 3D-Print
process, our machine honed
powdered metal granules with the
help of a laser, layer by layer, into
the required part,” explains Nikolai
Zaepernick, Business Development
Manager Automotive at EOS. “The
victorious team from Stuttgart
decided on our partner Within’s
software for the construction of
the CAD model, as it was the most
suited for the part and its purpose.
The information for the manufacture
of the part was provided for the
Direct Metal Laser Sintering
(DMLSTM
) machine from our
universally deployable software,
which had, so to say, translated
the information from the existing
3D-CAD-model. The result was
amazing and showed just how much
the young engineers already
understand about their subject.”
Once the team had designed the
steering stub axle, the production of
the first component parts followed
immediately. The fact that the
development and production time
could be significantly shortened
when compared to previously
utilized processes was important
for the team. There were a number
of reasons for the time savings.
One is that with additive manufac-
turing the need to build negatives or
mould forms falls by the wayside.
In addition the entire process,
from design through fabrication is
more precise, meaning that often no
reworking or refining is required.
In this case the constructors from
Stuttgart reached a high production
quality in a very short time with
minimal honing for fit, so that the
part was almost immediately
race-ready.
Results
The advantages can be summed up
in concrete figures: The weight of
the part was reduced by 660
grammes, saving the Rennteam
Uni Stuttgart 35%. At the same
time the engineers succeeded in
increasing the rigidity by 20% - big
numbers for motorsports, and
numbers that translate into faster lap
times and reduced fuel consumption.
The best testimony was delivered
by the team with the result in the
final race of the series – a victory
at the Hockenheimring that
crowned the Stuttgart race team
as Formula Student Germany
Champions 2012.
“We are thrilled to have been able
to bring the Formula Student
Germany 2012 title to Stuttgart.
The freedom in the construction
process offered by the DMLS
technology from EOS has played
an important role in our success,”
says Löw. All those involved have
shown with this victory that the
engineering profession can be a lot
of fun – and ultimately, that there
are a multitude of interesting and
exciting ways of responding to the
shortage of technical specialists.
And the allure of new technologies,
such as additive manufacturing,
can play a role in this, inspiring
down the line more and more
young people to take a serious
look at a career in engineering.
“We are thrilled to have been
able to bring the Formula
Student Germany 2012 title to
Stuttgart. The freedom in the
construction process offered by
the DMLS technology from EOS
has played an important role in
our success.”
Yannick Löw,
Rennteam Uni Stuttgart
Think the impossible. You can get it.
Status 11/2012. Technical data subject to change without notice. EOS is certified according to ISO 9001.
EOS GmbH
Electro Optical Systems
Corporate Headquarters
Robert-Stirling-Ring 1
82152 Krailling/Munich
Germany
Phone +49 89 893 36-0
Fax +49 89 893 36-285
Further EOS Offices
EOS France
Phone +33 437 49 76 76
EOS India
Phone +91 44 28 15 87 94
EOS Italy
Phone +39 0233 40 16 59
EOS Korea
Phone +82 32 552 82 31
EOS Nordic & Baltic
Phone +46 31 760 46 40
EOS of North America
Phone +1 248 306 01 43
EOS Singapore
Phone +65 6430 05 50
EOS Taiwan
Phone +886 3 657 63 51
EOS UK
Phone +44 1926 62 31 07
www.eos.info • info@eos.info

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Easing to victory – the Rennteam Uni Stuttgart wins the Formula Student Germany with EOS support

  • 1. Challenge Build a reliable, lightweight axle-pivot with high rigidity, in the shortest possible time. Solution Production of a topology- optimized steering stub axle using EOS technology. Results • Optimized: perfect form and contouring for a reduced weight by 35% and an increased rigidity by 20% • Speedy: significant shortage in development and production time • Safety: reliable on the track Facts Customer Case Study Automotive Easing to Victory – The Rennteam Uni Stuttgart Wins the Formula Student Germany with EOS support In the construction the student engineers employed for the first time an additive manufacturing process and the car went on to win the title. (Source: Rennteam Uni Stuttgart).
  • 2. Short profile The Rennteam Uni Stuttgart is an independent club composed of highly motivated students from a broad range of fields. It takes part in the Formula Student racing series, a competition for young engineers, across Europe, as well as being involved in other international com- petitions. Address Rennteam Uni Stuttgart Pfaffenwaldring 12 70569 Stuttgart (Germany) www.rennteam-stuttgart.de The greater the force in play, the greater the resulting counter-force – a relatively basic rule of physics. Such rules are particularly relevant in motorsports, where the stresses placed on the utilized materials are extreme. Taking the circuit at high speeds exposes both driver and car to the effects of such forces. The young constructors of the Rennteam Uni Stuttgart are constantly striving to optimize the construction process and the use of materials. More and more the sport demands that not only should the driver pilot the car ever quicker around the track but, within the principles of the Formula Student Germany series, he should do it safely. In the construction of the successful 2012 model the student engineers employed for the first time an additive manufacturing process in the building of the knuckles - and the car went on to win the title. EOS supported the team through its victorious Formula Student Germany season. Challenge The knuckle – also called the axle- pivot – connects the wheel axle with the wishbones and the track rod via a bearing. The braking system is then likewise fixed to it. The part conducts all the forces and momen- tum absorbed from the wheels to the wishbones and the tie rod, and on to the vehicle chassis itself. On the one hand, every constructor of an axle-pivot has the task of developing a part with the highest possible stability – otherwise the safety of the vehicle as a whole would be undermined. Besides a fracture, part deformation can also have serious consequences, as the kinematic design and, as a result, the drivability, would be negatively impacted. On the other hand, the wheel mounts cannot, for a number of reasons, weigh too much. Every additional gramme increases lap times, and the wheel mounts belong to the so-called unsprung mass of a vehicle. The less there is of this mass, the better the suspension and shock absorption will function. A low wheel-mount weight allows the car to sit better on the track – impor- tant for fast laps and safe racing. As a consequence, constructors are faced with the tricky task of finding the perfect balance between rigidity and weight. Young engineers choose additive manufacturing to tap the full potential of the part Thanks to additive manufacturing, the weight of the knuckles was reduced by 660 grammes in all. Numbers that were translated into faster lap times and reduced fuel consumption (Source: Rennteam Uni Stuttgart).
  • 3. Previous production technologies offered the Stuttgart race team too little room to maneuver in the search for this perfect balance. “The wheel mount we‘d been using over the last few years had already achieved a good balance between weight and rigidity, but we were sure we could improve on it,” explains Yannick Löw from the Rennteam Uni Stuttgart. “We produced the part using the classic precision casting process. This, of course, led to limitations in freedom of form, which meant that the part‘s potential could never be fully realized. Even back then we‘d decided that for the 2012 season we‘d investigate new, innovative ways of manufacturing the steering stub axle.” It didn‘t take long for the team to decide upon the path to take: The EOS-technology. Solution As early as the conceptual design phase, the engineers utilized the CAD software from EOS partners Within Technologies Ltd. Within is a young company, whose programmers wrote their software specifically for the additive manufacturing process. The program makes possible the optimization of latticed micro-structures of variable densities following examples found in nature. Thanks to this tool the constructors were able to match the part perfectly to the structural require- ments. In this way, they were able to give the knuckle precisely the required physical properties – light- weight plus rigidity. “By the simplified, so called, 3D-Print process, our machine honed powdered metal granules with the help of a laser, layer by layer, into the required part,” explains Nikolai Zaepernick, Business Development Manager Automotive at EOS. “The victorious team from Stuttgart decided on our partner Within’s software for the construction of the CAD model, as it was the most suited for the part and its purpose. The information for the manufacture of the part was provided for the Direct Metal Laser Sintering (DMLSTM ) machine from our universally deployable software, which had, so to say, translated the information from the existing 3D-CAD-model. The result was amazing and showed just how much the young engineers already understand about their subject.” Once the team had designed the steering stub axle, the production of the first component parts followed immediately. The fact that the development and production time could be significantly shortened when compared to previously utilized processes was important for the team. There were a number of reasons for the time savings. One is that with additive manufac- turing the need to build negatives or mould forms falls by the wayside. In addition the entire process, from design through fabrication is more precise, meaning that often no reworking or refining is required. In this case the constructors from Stuttgart reached a high production quality in a very short time with minimal honing for fit, so that the part was almost immediately race-ready. Results The advantages can be summed up in concrete figures: The weight of the part was reduced by 660 grammes, saving the Rennteam Uni Stuttgart 35%. At the same time the engineers succeeded in increasing the rigidity by 20% - big numbers for motorsports, and numbers that translate into faster lap times and reduced fuel consumption. The best testimony was delivered by the team with the result in the final race of the series – a victory at the Hockenheimring that crowned the Stuttgart race team as Formula Student Germany Champions 2012. “We are thrilled to have been able to bring the Formula Student Germany 2012 title to Stuttgart. The freedom in the construction process offered by the DMLS technology from EOS has played an important role in our success,” says Löw. All those involved have shown with this victory that the engineering profession can be a lot of fun – and ultimately, that there are a multitude of interesting and exciting ways of responding to the shortage of technical specialists. And the allure of new technologies, such as additive manufacturing, can play a role in this, inspiring down the line more and more young people to take a serious look at a career in engineering. “We are thrilled to have been able to bring the Formula Student Germany 2012 title to Stuttgart. The freedom in the construction process offered by the DMLS technology from EOS has played an important role in our success.” Yannick Löw, Rennteam Uni Stuttgart
  • 4. Think the impossible. You can get it. Status 11/2012. Technical data subject to change without notice. EOS is certified according to ISO 9001. EOS GmbH Electro Optical Systems Corporate Headquarters Robert-Stirling-Ring 1 82152 Krailling/Munich Germany Phone +49 89 893 36-0 Fax +49 89 893 36-285 Further EOS Offices EOS France Phone +33 437 49 76 76 EOS India Phone +91 44 28 15 87 94 EOS Italy Phone +39 0233 40 16 59 EOS Korea Phone +82 32 552 82 31 EOS Nordic & Baltic Phone +46 31 760 46 40 EOS of North America Phone +1 248 306 01 43 EOS Singapore Phone +65 6430 05 50 EOS Taiwan Phone +886 3 657 63 51 EOS UK Phone +44 1926 62 31 07 www.eos.info • info@eos.info