At Mettler Design, we were tasked with improving the efficiency and performance of three-wheelers by redesigning and optimizing their rear fork. The challenge was to employ topology optimization techniques to minimize material usage while maintaining strength and durability. This approach not only reduced unsprung weight—making the vehicle lighter and more energy-efficient—but also prepared the design for Additive Manufacturing (AM) methods, aligning with modern production technologies.
This project highlights our ability to combine product design, prototyping, and manufacturing expertise to transform customer requirements into practical, high-performance engineering solutions.
INITIAL DESIGN AS THE FOUNDATION
The existing rear fork design served as the baseline for our optimization study. By starting with this structure, we applied topology optimization simulations to refine the geometry. The component, manufactured in steel alloy, was carefully optimized to achieve targeted weight reductions while maintaining structural integrity and load-bearing capacity.
ITERATIVE REFINEMENT THROUGH SIMULATIONS
Using an iterative design process, we carried out multiple simulation cycles to refine the fork’s geometry. Each iteration brought improvements in material efficiency and performance, allowing us to gradually reach the most effective solution.
The outcome was an organic, optimized design that balanced weight reduction with mechanical strength. Our team then provided these simulation-driven envelopes to the client’s design department, who further developed the final production geometry based on our input.
FROM ENGINEERING TO PRODUCTION READINESS
Through this rigorous approach, we ensured the final design was lightweight, efficient, and manufacturable using modern techniques like additive manufacturing. By combining advanced engineering analysis with practical manufacturing considerations, we delivered a rear fork design that exceeded the client’s performance goals while remaining suitable for production.
This project underscores how Mettler Design leverages product design innovation, prototyping validation, and manufacturing expertise to deliver solutions that push the boundaries of performance and efficiency.
