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...by the many different designs we received from the GrabCAD Community for our underrun protection device challenge. It was a very technical topic, involving critical stiffness analyses and learning a new simulation software. The long list of resulting designs with so many different ideas on how to increase stiffness, reduce weight and make it look cool is therefore even more impressive! A big shout-out and thanks to all the participants who spent time and effort on ideas and designs, and finally testing their structural integrity using the SimScale platform – you did a superb job!
To choose our finalists, we first ordered all entries by their weight since mass was one of the most critical decision metrics for winning this challenge. We then checked the 30 lightest designs on the second most critical metric, regarding the stiffness requirements, and ran plenty of comparison simulations to make we chose the top designs. All winners passed their stiffness tests and we've included any applicable P1, P2, and P3 results. Finally, we had a long team discussion about the aesthetics of each design. The result is our ranking, below.
David’s model combines a very low mass with aesthetic contours in every part of the model. It almost seems that the holes are there for the looks of the device rather than due to weight reduction purposes. This design truly combines a low mass, high stiffness as well as an aesthetic, creative appearance. Very well done!
Weight (kg): 45
Passed stiffness test: Yes
P1: 350 MPa, 1.50 cm
P2: 324 MPa, 0.26 cm
P3: 295 MPa, 0.39 cm
Design rank: 2
Alex’s design of the underrun protection device realizes the hard technical constraints of the challenge in a design with many fluent lines and smooth transitions. The combination of the rolling parts with the holes in the structural members gives the design a very elegant look. From a stiffness point of view, the design avoids large changes in cross sections as well as sharp corners so that the distribution of forces works very well. Great work!
Weight (kg): 50
Passed stiffness test: Yes
P1: 366 MPa, 1.41 cm
P2: 396 MPa, 0.34 cm
P3: 259 MPa, 0.25 cm
Design rank: 1
Filip did a superb job in addressing the specific load case posed in this challenge by supporting the outer parts of the front shield with longer stiffeners while using shorter ones in the middle. This design approach, in addition to intelligent use of holes and a U profile for the shield front, makes the design very stiff while not using too much material. The playful cut-outs around the fixation points might be a matter of taste, but we love it! Nice job!
Weight (kg): 52
Passed stiffness test: Yes
P1: 387 MPa, 1.24 cm
P2: 229 MPa, 0.35 cm
P3: 267 MPa, 0.33 cm
Design rank: 3
Deus’ design features an eye-catching honeycomb structure that supports the front shield. In combination with the clean design of the front shield and the structural members, it gives the whole design a great appearance! We would love to see a crash simulation with this design. Nice job!
Weight (kg): 49
Passed stiffness test: Yes
P1: 201 MPa, 0.2 cm
Design rank: 6
The hollow structural members with holes for weight reduction as well as the intelligently chosen supports for P1, P2 and the P3 load cases make Amit’s model an outstanding design. From an aesthetic point of view it combines almost organic contours (supports) with hard technical components (clean front shield, fixation holes). Well done!
Weight (kg): 56
Passed stiffness test: Yes
P1: 355 MPa, 0.7 cm
Design rank: 5
With the bent front shield in combination with the four holes per structural member, BJ managed to create a clean looking design without many embellishments. At the same time, the model is light and stiff thanks to the supports that are attached to the important regions of the front shield. Great work!
Weight (kg): 55
Passed stiffness test: Yes
P1: 258 MPa
Design rank: 7
Arek’s design comes across very minimalistic in its looks while offering low mass and high stiffness. The cross piece as well as the different-sized mass reduction holes give it a very unique look! Nice job!
Weight (kg): 46
Passed stiffness test: Yes
P1: 352 MPa, 0.9 cm
Design rank: 10
Ioannis shows great engineering skills with his design by using all sorts of intelligent force distribution and mass reduction mechanisms: a (sort of) U-profile for the front shield, support for the critical regions, I-profiles for the structural members as well as intelligently placed holes for weight reduction. For the aesthetic component, we really like the increasing narrowness of the U-profile to the sides of the protection device as well as the triangular shaped holes in the structural members. Great work!
Weight (kg): 53
Passed stiffness test: Yes
P1: 278 MPa, 1.25 cm
Design rank: 8
Robin managed to create a smooth model despite tough technical constraints. The round contours close to the fixation holes as well as the interestingly shaped cut-outs in that region of the structural members give this design a special touch. The well-placed supports make sure it meets the stiffness requirements while being very light! Great job!
Weight (kg): 51
Passed stiffness test: Yes
P1: 337 MPa, 1.17 cm
Design rank: 9
Even after many a looong and heated discussion, our crew found it very tough to decide on the winners. We are truly impressed by the talent of the GrabCAD Community and especially the participants in our Challenge. It required not only creative and design skills, but also the skills of setting up FEA analyses and proving the structural integrity of the design. Once again a big, "Thank you!," to all the participants!
We want to give a shout out to those that did not make it into our Top 10 winners, but offered a lot of hard work and created great entries. Have a look at their engineering skills, which are in no particular order, as well!
The many straight lines give it a clean and technical look! Nice job!
Very futuristic! Great work!
Especially the different sized holes on the side look great in addition to being very light. Great engineering skills!
The multiple different holes combine lightweight design with great looks. Nice job! Apparently can also be used for racing vehicles (see rendering!).
Impressive use of topology optimization to solve the task. Nice!
The stiffening beams look great!
Clever use of standard profiles, easy to manufacture while being very light. Great engineering work!
Very minimalistic design while being very light. Great work!
Sara Sigel
Johannes Probst
Alexander Fischer
David Heiny
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