The 2013 SRT Viper Carbon Fiber X-Brace, styled by Chrysler's Product Design Office (PDO), is as much of a work of art as it is an engineered structural component. Presented in this paper is the design evolution, development and performance refinement of the composite X-Brace (shown in Figure 1). The single-piece, all Carbon Fiber Reinforced Plastic (CFRP) X-Brace, an important structural component of the body system, was developed from lightweight carbon fiber material to maximize weight reduction and meet performance targets. The development process was driven extensively by virtual engineering, which applied CAE analysis and results to drive the design and improve the design efficiency. Topology optimization and section optimization were used to generate the initial design's shape, form and profile, while respecting the package requirements of the engine compartment. Concept selection, geometry sensitivity studies and concept refinement methods were then used to optimize the design, considering manufacturing constraints and all critical load cases. A close partnership between Chrysler Body Engineering, PDO and Plasan Carbon Composites lead to the completion of a successful CFRP X-Brace to be sold in the aftermarket by Chrysler's Mopar parts division.
