Beginner Tutorials

Formula Student - Part 5 - Topology Optimisation

October 30, 2025

The video walks through setting up a topology optimisation study for a Formula Student upright by isolating the wheel assembly and preparing a simplified design envelope with key mounting features. Loads from braking, steering, suspension and tyre contact are applied using remote forces and fixtures. The study aims to reduce mass by 50% while maintaining a minimum factor of safety, with preserved regions ensuring manufacturability. After meshing and running the optimisation, the resulting geometry highlights removable material and improved structural efficiency. The final smoothed body shows a significant weight reduction and provides a basis for further refinement, machining or 3D printing.