What the study found
The study found that a hybrid lightweight rim design for an electric Formula Student race car could meet the required stiffness and safety requirements while reducing mass. The final design used woven carbon fiber fabric with a metallic center disk and achieved the stated performance targets.
Why the authors say this matters
The authors say the study provides a transferable methodology for carbon fiber reinforced polymer (CFRP, a carbon-fiber-based composite material) rim design that combines laminate design, manufacturing constraints, and vehicle integration constraints. They also state that the rim’s mass reduction is expected to improve acceleration, braking response, and ride quality in the Formula Student car.
What the researchers tested
The researchers carried out a structured review of existing CFRP rim and wheel concepts, then developed and compared three design options: a composite rim with an aluminum center disk, a full composite spoke rim, and a full composite flange rim. They used finite element analysis (computer-based structural simulation) and iterative laminate sizing, and also incorporated manufacturing considerations through enhanced numerical simulation.
What worked and what didn't
The hybrid rim with a metallic center disk was selected because it fit the existing vehicle architecture and was considered feasible to manufacture. The final symmetric laminate stack of alternating 0° and 45° woven carbon fiber plies met the camber-angle stiffness requirement, with safety factors of about 1.5 in compression and 1.8 in tension, and showed a 49% weight saving compared with an aluminum reference. The study also says this reduction approximately halves the rim’s polar mass moment of inertia and, together with a 3% vehicle mass reduction, is expected to improve vehicle performance.
What to keep in mind
The abstract does not describe detailed limitations beyond the stated resource and time constraints typical of Formula Student projects. The paper focuses on a specific Formula Student race-car application, so the results are presented within that scope.
Key points
- A hybrid composite rim with a metallic center disk was selected from three design options.
- The final design used a symmetric laminate of alternating 0° and 45° woven carbon fiber plies.
- The rim met camber-angle stiffness requirements and showed safety factors of about 1.5 in compression and 1.8 in tension.
- The design achieved a 49% weight saving versus an aluminum reference.
- The authors present a transferable methodology that combines laminate design, manufacturing constraints, and vehicle integration constraints.
Disclosure
- Research title:
- Composite rim design achieved lower mass and required stiffness
- Authors:
- Kevin Klemt, Raffael Bogenfeld, Jean Lefèvre, Louisa Türke
- Institutions:
- Deutsches Zentrum für Luft- und Raumfahrt e. V. (DLR), B. Braun (Netherlands), Technische Universität Braunschweig
- Publication date:
- 2026-02-26
- OpenAlex record:
- View
- Image credit:
- Photo by HScarphotographie on Pixabay · Pixabay License
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