The rear aluminium bulkhead is a critical structural component in a Formula SAE race car, providing essential support for both the powertrain and suspension systems. For the 2020 season, I designed our team’s first detachable Aluminum 6061 bulkhead, which significantly enhanced the reliability and precision of the rear assemblies.

The design optimized the layout to incorporate 75% of the rear suspension mounts, including four wishbone, two rocker, and two spring-damper mounts. Additionally, the bulkhead effectively supported the majority of the drivetrain components, featuring mounts for the engine, drive spool, and sprocket.

To achieve optimal strength while minimizing weight, I utilized topology optimization in ANSYS. The bulkhead was CNC machined, resulting in over 80% accuracy in the rear assembly mountings. This precision machining process eliminated the need for complex welding fixtures, allowing for the use of bolted joints instead of welded connections. The final part was anodized to enhance its corrosion resistance and durability, finished in our signature red color.

Overall, the bulkhead design improved assembly accuracy which eliminated rear drive shaft misalignment and chain tensioning issues ensuring smooth operation on the track. Click HERE to see the detailed report.

Aluminium Bulkhead CAD model

FEA of Final Design

Red Anodized

Suspension Mounts Bolted to Bulkhead