Case Study 6 – Design Analysis and Manufacture

Design Analysis and Manufacture of Motorsport Components

Durable lightweight bracket required for high load motorsport braking system.

Design requirements centred around execution of a performance improvement.

Strength and reliability was paramount but unsprung mass had to be minimized for optimal suspension performance.

Load case for analysis was derived from braking system operating parameters.


  • 3D CAD used for design of bracket and to generate manufacturing drawings.
  • Design For Manufacture (DFM) principles applied to maximise manufacturing efficiency and minimise cost.


  • Classic calculations carried out to determine bracket loading and basic stresses
  • Finite element analysis used to verify classic calculations and provide detailed stress distribution for fatigue load study