Recently, engineering students of Rennteam Uni Stuttgart improved their Formula Student Germany car (and won the Formula Student Germany overall competition) with a revamped version of a key component of their car, the knuckle. The knuckle is a solid one-piece linkage that connects the vehicle’s axle, bearings, and brake system. It is also the pivot point of the steering system and wheels. Using direct-metal laser sintering (DMLS) to build a better-optimized knuckle, the Uni Stuttgart team made the knuckle with hollow spots to reduce weight while maintaining rigidity. DMLS was the only method capable of producing a part this complex and optimized.
Read more by Lindsey Frick, Machine Design, March 3, 2014