Engineering Consulting for the Motorsport Sector

Motorsport Engineering: Speed, Precision and Innovation

In the life cycle of a racing car, speed of development is as critical as speed on the track. Already the engineering partner of Formula 1 racing teams and High-Performance manufacturers, Asotech fits into the teams' workflow as an R&D accelerator. Our organizational and methodological structure allows us to adapt quickly to typical racing urgencies, turning the requirements of technical regulations (e.g., FIA, ACO) into production-ready mechanical components, thus cutting down time-to-track.

Extreme performance under stringent regulations

Today's racing teams and manufacturers face unprecedented engineering challenges: reducing mass while meeting Budget Cap constraints, thermal management in increasingly extreme aerodynamic packaging, and ensuring driver safety. In this scenario, traditional engineering is not enough.

It requires an approach that aims for maximum performance through a lean working methodology and constant operational flexibility, capable of combining parametric CAD design with advanced multiphysics simulation. This is the only way to accurately predict the behavior of the car before even building the first prototype, turning responsiveness into a competitive advantage.

Enhance your motorsport projects with reliable and qualified support

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The challenges of the motorsport industry

The automotive industry is characterized by tight technical constraints, compressed development time, and very high quality and integration requirements. Key challenges include:

1. Stiffness-to-Weight FEM Optimization.

The main challenge in structural design is to reduce weight without compromising the stiffness and durability of various components.Through topological optimizations and the advanced use of composite materials and light alloys, structures with the best weight-to-strength ratio can be achieved. Fatigue tests performed with increasingly sophisticated software within multybody analyses advanced allow for continuous improvement of components.

2. Thermal management of thrusters and batteries

With the evolution of hybrid and electric automotive technologies, thermal management has taken on a crucial role: this is where the focus is on optimizing systems for the development of increasingly high-performance batteries. The main challenge is to design solutions that ensure proper heat transfer without penalizing aerodynamic efficiency, while ensuring the reliability of critical components. The design phase can be complemented by advanced simulation tools such as CFD fluid dynamic analysis and power electronics-specific modules such as Ansys Maxwell and Icepak.

3. Crash & Passive Safety

In recent years, passive safety standards in the automotive sector have reached levels of excellence, thanks to the increasing focus on impact dynamics, analyzed through experimental testing and advanced simulations. Asotech has established deep expertise in this area, specializing in the development of optimized impact structures using explicit FEM simulations conducted in the LS-DYNA environment.

4. Digital validation: FEM/CFD and thermal for rapid decisions.

Innovating within stringent technical regulations is the essence of motorsport. Through precise calculation methodology and flexibility in finding cutting-edge technical solutions, we support teams in interpreting FIA/ACO regulations. We provide all necessary documentation for thehomologation of safety components, ensuring full geometric and structural compliance required without ever compromising the pursuit of extreme performance.

We turn your vision into performance. Let’s design your next challenge together.

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Motorsport engineering consulting services

Tailor-made solutions for our customers

Aerodynamic Simulations (CFD)

Using Ansys Fluent for external flow analysis, vertical load optimization(Downforce) and Drag reduction. Collaboration with wind tunnel department for validation of aerodynamic mapping(Aero Maps) on cars and motorcycles.

Internal Fluid Dynamics and Thermal Management

  • Cooling Systems: Sizingbrake ducts (brake ducts) and radiators.
  • Electronics Cooling: Dedicated simulations with Ansys Icepack and Maxwell for thermal management of battery packs, inverters and PCBs, optimizing heat transfer in reduced packaging.

Structural FEM, Fatigue and Passive Safety Calculation

Static, dynamic and Multibody analyses for fatigue testing of components. Explicit dynamics simulations (LS-DYNA) for the design of impact structures(Crash boxes) and structural fuses, ensuring compliance with regulatory crash tests.

Suspension and Chassis Components

We develop complete kinematics and structural components such as uprights (hub carriers), wishbones, rockers, and anti-roll bars. The primary objective is to minimizeunsprung masses (unsprung masses) while ensuring maximum torsional stiffness and resistance to peak loads typical of curbs and hard braking.

Design in Composite Materials

Advanced engineering of carbon fiber components, including flat bottoms, bodywork, and aerodynamic ducts. We curate every step of the process: from defining Class A surfaces to laminating ply-books to integrating metal inserts(hardpoints) and honeycomb cores to optimize the weight-to-strength ratio.

Powertrain Integration

We manage the complex packaging of auxiliary systems within the chassis. We designdry sump oil tanks(dry sump tanks) with internal flow analysis, vibration-optimized engine mounts, and piping bracket systems, ensuring mechanical accessibility and rapid maintenance during pit operations.

Looking for an engineering partner for the upcoming season?

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Approach to motorsport engineering consulting

How We Work

We Listen to Your Needs

We start with an in-depth dialogue to understand the specific requirements of your project and the challenges you want to address.

We Create Tailored Solutions

Our experts develop customized numerical models using the best available technologies to deliver accurate and reliable results.

We Deliver Certified Results

We validate each simulation with experimental data, ensuring that the proposed solutions meet your expectations and guarantee project success.

Our motorsport projects

Success stories that demonstrate our expertise.

Do You Have a Project in Mind? Let’s Talk!

We are here to help you transform complexity into reliable solutions, working alongside you in every engineering challenge.