Designcontest winner evolved into R&D testcase
In addition to collaborations and commissioned work, we enjoy dedicating time to experimenting with innovative design and engineering tools. The best way to evaluate them in practice, without the risk of stagnation on commercial projects, is by testing these new workflows in our own R&D side project.
The Elementz Evo is the evolution of the Burton Elementz Kitcar, the winning concept of both the Burton Car Company Design Contest and the international SolidWorks model contest.
While the composite body of this fully revised design remains a secret for now, we can provide a sneak peek of the newly developed chassis and suspension system. The Evo features a mid-engine setup and pushrod suspension, rather than the classic front wheel drive 2CV chassis used by Burton Car Company. However, the core of the concept remains unchanged: a high dose of adrenaline is guaranteed by the significantly improved power-to-weight ratio and the extremely open design.
Powered by a BMW K1200RS motorcycle engine, K1200LT gearbox, BMW 1-Series differential, and driveshafts, the goal is to keep the dry weight of this ‘Trackday Monoposto’ under 400 Kg. An ambitious goal, but certainly not impossible with no more functionality on board than strictly necessary.
All drivetrain components have been digitized through 3D scanning to create a real-world reference for the 3D design and engineering process. This ensures seamless integration of the drivetrain, spaceframe, suspension, and bodywork. To guarantee a perfect alignment of the drivetrain, all interfaces and mounting positions have been double checked using 3D printed measuring and evaluation tools.
The driver is the starting point of the layout/packaging, and the central position is determined through a combination of a 3D mannequin and a 1:1 mockup of the seating position and controls. Then, all other components are arranged based on optimal weight distribution and the lowest possible center of gravity.
Subsequently, SolidWorks assemblies are imported into Gravity Sketch: Virtual Reality design software for 3D modeling and sculpting in the true sense of the word. These engineering assemblies serve as the perfect base for an efficient process from the initial 3D concept sketches to the final design of the bodywork.
Newly developed parts are prototyped with our 3D printer and tested for assembly and freedom of movement. A highly cost effective solution to evaluate and optimize parts before ordering the relatively expensive CNC production parts.
From quick notebook sketches to VR, a toolbox filled with software, hardware, and experimental R&D tools. A continually optimized daily workflow, the result of curiosity and design passion.
