Computer Aided Design:

Computer Aided Design is a vital engineering tool that is used throughout motorsports. CAD is software which allows the engineer to embody components before manufacture. The main benefit of CAD is that it allows for rapid yet complex 3D designs to be made. These assemblies are to scale and they allow the designers to see if their calculations and designs will work when manufactured. For example, an F1 team may design a suspension system for their car including the wheel hub etc, and from the CAD assembly they may realise that all of their sensors and brake components won’t fit into the wheels ‘cake tin’. This discovery can then be rectified before any parts have been manufactured. The amount of cost saving CAD brings is incredible. F1 teams also use other functions of CAD such as stress strain analysis, fatigue analysis and environmental effects analysis of using specific materials. CAD is forever increasing in importance, especially as the era of 3D printing comes upon us.

The basic stages of CAD:

•          Create a design specification (including: measurements/positioning, materials and design decisions)
•          Begin modelling individual components
•          Assemble components 
•           Analyse assembly of design faults / problems
•      Create the final engineers’ drawings for manufacture

 This image shows an assembly of a Formula Student car’s rear suspension and powertrain. I was the suspension design engineer in this group task, and as you can see, it is quite complex! (Even without a proper chassis)

Imagine if this was powertrain and suspension system of a Formula 1 car. The engineers would have to work around the physical limitations of the rear of the car, now that it includes an eight speed gearbox, energy store and the MGU-K. A relatively simple thing such as more occupied volume at the rear of the car can be a very large challenge because it will affect geometries and aerodynamics. We saw the return of dog legged wishbones on some cars earlier this year (Force India), most likely so that geometry calculations could be maintained.

Without CAD, the incredible F1 cars that we see today would be all but impossible to create. There are so many variables in F1 and CAD software can take out a considerable amount of them.  CAD is fundamental to manufacture the many complex and intricate components of an F1 car.

 I hope that I have given you a good, quick insight into the CAD work in motorsport and that you now understand more about how the engineers design these cars. I apologise if there is not enough information, or if it is too confusing, but I am learning and experimenting how to convey all of this information and things will improve soon.

Thank you for visiting, please do ask questions, either in the comments or on my Twitter @HybridAliF1

Ali