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The purpose of this paper is to implement the generative design as an optimization technique to achieve a reasonable trade-off between weight and reliability for the control arm plate of a double-wishbone suspension assembly of a Formula Student race car.

The generative design methodology is applied to develop a low-weight design alternative to a standard control arm plate design. A static stress simulation and a fatigue life study are developed to assess the response of the plate against the loading criteria and to ensure that the plate sustains the theoretically determined number of loading cycles.

The approach implemented provides a justifiable outcome for a weight-factor of safety trade-off. In addition to optimal material distribution, the generative design methodology provides several design outcomes, for different materials and fabrication techniques. This enables the selection of the best possible outcome for several structural requirements.

This technique can be used for applications with pre-defined constraints, such as packaging and loading, usually observed in load-bearing components developed in the automotive and aerospace sectors of the manufacturing industry.

Using this technique can provide an alternative design solution to long periods spent in the design phase, because of its ability to generate several possible outcomes in just a fraction of time.

The proposed research provides a means of developing optimized designs and provides techniques in which the design developed and chosen can be structurally analyzed.

Aarhus Kommunes Biblioteker (Teknisk Bibliotek), Ingerslevs Plads 7, Aarhus, Denmark. Representative: V. NEDERGAARD PEDERSEN (Librarian).