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Frame Stiffness & Weight Optimization

UW Formula Electric · Nov 2025 – Mar 2026

An Ansys study to find where tubing changes add the most torsional stiffness to our frame, and where we can reduce weight.

Ansys torsional stiffness model of the frame
Largest gain: added tubes (green) for +24% stiffness at 621 g
Most efficient addition: +22.5% stiffness for 310 g
Thinner-walled tube swap (green): 457 g saved for a 0.5% stiffness loss
A rejected option: +6.7% stiffness but 923 g added
Extra check: modelling the front enclosure plate (+1.9%)

Ansys torsional stiffness model of the frame

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Tools: Ansys, SolidWorks, Excel

The trade-off

Each option is one point: how much weight it adds (or saves) against how much stiffness it gains, compared with the original frame (1232 Nm/deg). The best options sit high and to the left.

Key resultsOther options tested
Stiffness change vs. weight change for each frame option11 options tested in Ansys. Most added tubes gave under 8% more stiffness for 200 to 1050 g. One added tube gave 22.5% for 310 g, a pair gave 24% for 621 g, and a thinner tube swap saved 457 g for a 0.5% loss.0%+5%+10%+15%+20%+25%-500 g0 g+500 g+1000 gWeight changeTorsional stiffness change457 g saved, −0.5%Most efficient: +22.5% for 310 gLargest gain: +24% for 621 g
Stiffness from Ansys FEA. Hover or tap a point for its numbers.
Show the numbers
ChangeWeightStiffness
Thinner-walled tube swap-457 g-0.5%
Added tube+310 g+22.5%
Added tubes+621 g+24.0%
Added tube+319 g+0.5%
Added tube+687 g+6.5%
Added tube+345 g+0.5%
Added tube+210 g+0.1%
Added tube+923 g+6.7%
Added tube+1053 g+7.4%
Added tube+660 g+5.2%
Added tube+1014 g+5.8%
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