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Case Study

Futuro Solare Uses Simulation to Optimize Solar-Powered Cars

"With the Ansys Discovery solution, I was positively impressed by the software’s speed and efficiency, even when running it from an external SSD. It has proven to be an invaluable tool for simulating and optimizing our suspension design prior to production."

— Giovanni Sapienza
Intern, Futuro Solare

The solar vehicle industry today represents one of the most advanced frontiers in sustainable transportation innovation, offering concrete solutions for future mobility based on renewable energy and cutting-edge engineering technologies.
Within this context, Futuro Solare, through the use of Ansys simulation tools, has optimized its solar-powered vehicle designs, improving overall efficiency, reducing structural weight, and refining key components such as suspensions and powertrains. The methodological approach adopted by Futuro Solare also aims to train and inspire new generations of engineers and designers, actively contributing to the development of responsible and sustainable mobility solutions.

Challenges

Throughout the development process of its solar vehicle, Futuro Solare faced significant technical challenges, particularly in managing limited resources and meeting complex engineering requirements.

Analyzing and validating numerous design variants, materials, and systems under real-world conditions would have entailed prohibitive costs and timeframes. In particular, the suspension system required an in-depth study to ensure both reliability and desired dynamic performance, while the team also worked in parallel to optimize motor efficiency and aerodynamic flow.

Without the support of advanced simulation tools, achieving the project's sustainability and innovation goals would have been extremely difficult.

fem-analysis-upper-suspension

FEM Analysis upper suspension

Engineering Solutions 

Using Ansys solutions, Futuro Solare overcame operational constraints and refined the design of its solar vehicle at every stage of development. The various simulation software tools enabled the team to analyze critical parameters such as suspension behavior, electric drivetrain efficiency, and overall aerodynamics, significantly reducing the need for an excessive number of physical prototypes.

Thanks to precise simulations, the team optimized material usage, improved energy transfer through refined suspension configurations, and addressed thermal and magnetic issues in the propulsion system through targeted solutions.

Furthermore, Futuro Solare successfully experimented with topology optimization using Ansys Discovery™ software, identifying innovative and lightweight geometries for structural components while maintaining mechanical integrity and functionality. This led to direct improvements in the vehicle’s energy efficiency.

The high flexibility of Ansys tools also enabled full remote collaboration between students, tutors, and researchers, allowing for an effective integration of academic education with practical field applications.

archimede-with-the-italian-flag-in-adelaide

Archimede with the Italian flag in Adelaide

Benefits

  • Weight Reduction: A 1 kg weight reduction on suspension components, delivering positive effects on energy efficiency, dynamic behavior, and vehicle range. This approach enabled rapid evaluation of multiple material combinations and structural optimization for durability and performance.
  • Motor Efficiency: Enhanced power conversion efficiency thanks to improved torque density and detailed analysis of thermal and magnetic properties. These optimizations led to reduced energy losses and more effective power transfer during operation.
  • Aerodynamic and Thermal Optimization: Targeted CFD simulations enabled optimization of airflow around the vehicle, while simultaneously improving the cooling of electronic systems and battery packs, resulting in greater overall system reliability and global performance.
fem-analysis-von-mises-stress

FEM Analysis (Von Mises Stress)

student-at-the-computer-with-ansys-discovery

Student at the computer with Ansys Discovery