Define
Establish suspension architecture, packaging constraints and required pick-up points.
DESIGN · ANALYSIS · OPTIMISATION
REAR SUSPENSION DESIGN
First-principles suspension development combining mathematical modelling, parametric CAD, structural analysis and component design.
PROJECT OVERVIEW
From suspension geometry to a complete rear-corner assembly.
The project focused on the design and development of a rear suspension system for a performance vehicle.
Mathematical modelling was used to optimise suspension geometry and pick-up point locations, supported by finite element analysis and thermal simulation to assess structural performance and brake heat dissipation.
The final design combined suspension kinematics, structural efficiency, packaging and manufacturability into a fully integrated rear suspension assembly.
DEVELOPMENT PROCESS
Engineering from first principles.
Model
Develop mathematical models describing suspension geometry and component behaviour.
Optimise
Use MATLAB-based optimisation to investigate geometry and loading configurations.
Validate
Apply structural and thermal simulation before integrating components into the final assembly.
01
KINEMATICS & PARAMETRIC DESIGN
Wishbone & Upright Development
The suspension architecture was defined using chassis and upright pick-up points, creating a parametric foundation for rapid geometry development.
- Defined the principal suspension axes through chassis and upright pick-up points.
- Linked key geometry parameters to MATLAB-based optimisation.
- Evaluated multiple design variations efficiently.
- Developed suspension kinematics, structural efficiency and packaging constraints in parallel.
- Used the resulting geometry as the basis for detailed CAD and FEA validation.
02
MATHEMATICAL MODELLING
Suspension Geometry
Mathematical representation of the final wishbone, pushrod and toe-link geometry allowed the suspension architecture to be assessed before detailed component development.
MATLAB representation of suspension hardpoints and link geometry.
Hardpoint Definition
Chassis and upright pick-up points were defined as the basis of the suspension architecture.
Kinematic Model
Wishbone, pushrod and toe-link positions were represented mathematically to understand wheel movement.
Design Input
The resulting geometry informed detailed CAD development, packaging and subsequent structural validation.
03
STRUCTURAL DESIGN
Upright Design & Validation
The upright was developed as a structural interface between suspension, wheel and braking systems while balancing stiffness, mass, packaging and manufacturing requirements.
- Developed a manufacturable upright geometry around suspension and wheel-system interfaces.
- Evaluated structural loading through finite element analysis.
- Refined geometry around load paths and highly stressed regions.
- Considered assembly access, packaging and component interfaces.
- Produced detailed engineering drawings for manufacture.
DESIGN PHILOSOPHY
Geometry was not developed in isolation — every component formed part of the complete rear-corner system.
SYSTEM INTEGRATION
Rear Corner Subsystems
The suspension was developed alongside the wheel, brake, torque-transmission and wheel-hub systems to ensure the final design functioned as an integrated assembly.
04
Wheel Rim
Detailed wheel assembly design including component architecture, manufacturing drawings and exploded assembly.
05
Brake System
Brake disc and caliper integration developed around the suspension and wheel packaging envelope.
06
Torque Transmission
Transmission components designed to transfer drive torque through the hub while maintaining packaging and structural requirements.
07
Wheel Hub
Wheel-hub design combining bearing interfaces, spline geometry and torque-transfer requirements.
08
MATLAB OPTIMISATION
Wheel Hub & Spline Optimisation
MATLAB-based modelling was used to optimise spline geometry before transferring the resulting geometry into detailed CAD.
- Defined contact pressure, engagement angle and tooth count as primary optimisation parameters.
- Evaluated stresses generated by torque transmission.
- Considered both peak and cyclic loading conditions.
- Incorporated strength, fatigue, temperature and manufacturability into material selection.
- Generated control points that could be transferred directly into CAD.
09
COMPONENT DEVELOPMENT
Individual Components
Individual components were developed and validated before being brought together within the complete rear-corner assembly.
10
FINAL INTEGRATION
Master Assembly
The final stage brought the suspension, upright, wheel, braking and torque-transfer systems together as one integrated rear-corner assembly.
Cross-Section of Master Assembly
Integrated Suspension Assembly
PROJECT REFLECTION
Designing the system, not just the component.
This project developed my understanding of how analytical modelling, optimisation and detailed mechanical design can operate together within a single engineering workflow.
Rather than treating suspension components independently, the project required consideration of kinematics, load paths, packaging, structural behaviour, manufacturing and system integration throughout the design process.