Lightweight Design of Lattice Structure for Racing Car Suspension Rocker Arms Based on 3D Printing Technology

ZHOU Shengjie; LIAO Luhai; LI Fengguang; HU Shengbo; LIU Jianyong

doi:10.3969/j.issn.1674-6457.2026.02.017

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (2) : 183-195. DOI: 10.3969/j.issn.1674-6457.2026.02.017

Additive Manufacturing

Lightweight Design of Lattice Structure for Racing Car Suspension Rocker Arms Based on 3D Printing Technology

ZHOU Shengjie, LIAO Luhai, LI Fengguang^*, HU Shengbo, LIU Jianyong

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Abstract

The work aims to analyze the mechanical properties of six lattice structure units (Octet, Kelvin, Fluorite, Diamond, Schwarz, and Gyroid) under different working conditions, and screen out the optimal lattice structure for lightweight design so as to address the lightweight design requirements of racing car suspension rocker arms. The six array lattice structure units were constructed using nTopology software with a porosity set to 50%. Finite element analysis was employed, with consistent mesh division for all six structures. Their displacement and stress performances were compared under four working conditions (tension, compression, torsion, and bending) with a 4 kN load. Under compression and bending conditions, the Schwarz lattice exhibited the optimal displacement (0.013 3 mm, 0.025 mm) and stress (128.10 MPa, 256.96 MPa). When applied to the racing car suspension rocker arm, the redundant materials were removed through hollow design, resulting in a reduction in volume from 424 236.70 mm³ to 269 888.33 mm³, a decrease in mass from 1.192 kg to 0.758 kg, and an increase in specific strength by approximately 57.3%. The maximum stress of the racing car suspension rocker arm was 38.62 MPa, which was much lower than the maximum stress of 251.5 MPa under high safety factor; the maximum displacement was 0.27 mm, far below the displacement threshold of 1.155 mm under high safety factor; the maximum strain was only 0.05%, significantly lower than the ultimate strain of 0.35% under high safety factors. The material did not enter the plastic deformation stage, indicating sufficient safety margin. The application of the Schwarz lattice in racing car suspension rocker arms achieves significant lightweighting with sufficient safety margin, further expanding the application scenarios of lattice structures in automotive engineering. It is particularly valuable for key components subject to complex loads, providing an innovative solution for the lightweight design of automotive parts.

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3D printing / lattice structure / mechanical properties / lightweight design / finite element analysis

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ZHOU Shengjie, LIAO Luhai, LI Fengguang, HU Shengbo, LIU Jianyong. Lightweight Design of Lattice Structure for Racing Car Suspension Rocker Arms Based on 3D Printing Technology[J]. Journal of Netshape Forming Engineering. 2026, 18(2): 183-195 https://doi.org/10.3969/j.issn.1674-6457.2026.02.017

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Funding

Key Laboratory of Automotive Power Train and Electronics (Hubei University of Automotive Technology) (ZDK12023B06); Key Project of the Innovation and Development Joint Fund of Hubei Provincial Natural Science Foundation (2024AFD093); Key Project of the Hubei Provincial Department of Education (D20221801); Wudang Talent Plan Science and Technology Leading Talent Project (WDREJH-KJLJRC20231)