Formula E's Pushrod Suspension System (personal)
With this 3D visualization for Formula E's innovative pushrod suspension system, I am proud to share a few insights into this project. This system represents a critical blend of mechanical engineering and
cutting-edge design that delivers optimal performance on the track. My role involved translating a complex technical blueprint into a detailed, high-fidelity 3D model, which may allow engineers and racing teams to analyze and refine the suspension system's behavior under various conditions. Rendering carbon fiber of the rods, for example, illustrates how an attribute can be simulated digitally for further development toward the advancement of each material and its utility. This approach not only aids in the design and testing phases but also enhances educational materials and presentations for stakeholders.
Process and Technique
Objective - To create a highly detailed rendering of the Formula E pushrod suspension system for engineering analysis and education. To render with a rig that allows simulation of flex and load faced by Formula E cars under various conditions.
Research - Studied CAD references,schematics and engineering references to ensure model accuracy. Incorporated in real-world dimensions and high fidelity resources for precise surface and component creation including rocker arm, dampers and suspension arms.
Application:
Modeling - The visualization process included precise modeling of each component, realistic simulation, and dynamic rendering to ensure clarity and accuracy. I first modeled each component of the suspension system separately and then combined them. The shock absorbers and axel were the trickiest part of the topology.
Surface creation - After the modeling, Arnold's materials were combined with Autodesk Maya for the texturing and shading. The carbon fiber material required multiple layers of bump mapping and shading. PBR workflows and HDRI was used for realistic lighting and reflections. Surface realised was enhanced with ambient occlusion, precise texture mapping and projections. Maya’s Arnold Renderer was used for photorealistic outputs. The idea behind this render was to make it as realistic as possible, so the shading and texturing were a crucial aspect of the look and feel.
Rendering - After creating shades and materials, the model was then rendered using Arnold renderer. The set required lighting that adequately interacted with the model. For this, each aspect of lighting (ray tracing, shadows, number of rays, etc. ) was manually tweaked to create perfect interaction with the materials and shades (refraction, reflection, shading, opacity) in play. I faced some challenges with lighting and reflection of the metallic surface and the carbon fiber material, tweaking and adjustment of the materials resulted in a more realistic output.
The pushrod suspension is a testament to how form and function come together in motorsport, and visualizing its intricacies has been a rewarding challenge. It’s a pleasure to contribute to innovations that push the boundaries of electric racing performance. I wished to create an animated simulation of the system but was limited by heavy-output animated renderings and hardware capabilities. This project serves as the perfect example of how I want to use my skills as a visualizer to create digital renderings of products and experiences for the simulation of cutting-edge engineering technology. he insights into mechanical engineering, simulative visualization and identification of flaws that enable optimization through testing allows theoretical concepts in engineering to meet practical design workflows. The visualization adds educational value with an added intuitive understanding of suspension mechanics. The insights into mechanical engineering, simulative visualization and identification of flaws that enable optimization through testing allows theoretical concepts in engineering to meet practical design workflows.
3D Model Link:
