Design and Optimization of a Lightweight Automotive Chassis for Sustainable Mobility

Abstract

This paper presents the design and development of a lightweight Formula Student chassis aimed at improving performance, sustainability, and energy efficiency in a Formula Student race car. The chassis was engineered to be 20–30% lighter than the previous design without sacrificing structural strength. Advanced design techniques, including 3D Computer-Aided Design (CAD) modelling and Finite Element Analysis (FEA) simulation, were employed to optimize the chassis geometry and validate its structural integrity under load conditions. High- strength lightweight steel tubing (hollow "black pipe" and Schedule 40 pipe) was selected to reduce weight while meeting safety requirements. Simulation results indicate that the new design can withstand expected forces with adequate safety margins, and the weight reduction contributes to improved acceleration, handling, and energy efficiency of the vehicle. The prototype SLChassis was integrated into a 135cc Formula Student Malaysia 2025 race car, which achieved second place in the endurance race event and 4th in the design category. These results demonstrate the effectiveness of the lightweight chassis in enhancing vehicle performance. The innovations from this project underscore the importance of lightweight design and material optimization in sustainable mobility. This paper details the design methodology, simulation validation, and performance outcomes of the chassis, highlighting its potential for broader application in energy-efficient and sustainable vehicle engineering.