Automotive Steering Knuckle Redesign (Bachelor's Thesis - Honors Distinction, 9.3/10) →
- Reverse engineered a Ford Focus Active steering knuckle using 3D scanning and mesh processing.
- Redesigned the component through topology optimization, balancing weight reduction, structural performance and manufacturability.
- Achieved a 33.3% weight reduction (from 6.3 kg to 4.2 kg) while maintaining a safety factor > 2 under critical loading conditions.
- Performed CAD modelling, FEA and structural optimization considering sustainability and manufacturing constraints.