Minibaja Frame Design using Topological Optimization and Impact Testing

The search of lighter components and frames in racing competitions is of extreme importance. The usage of a structured design methodology and optimization processes leads to significant weight and design time reductions. In this work the Finite Element Method and optimization tools based on the strain energy approach are used to develop a lightweight Minibaja frame. To assure that the design is also safe, dynamic analysis of a frontal impact against a tree at 25 km/hr and a roll over roof crush test according the FMVSS 216 are carried out. The resultant structure is 9% lighter than its predecessor fulfilling all static and dynamic specifications.