F1 Style Active Suspension
F1 Style Active Suspension
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Compact pushrod double-wishbone suspension module with servo actuated ride height control, designed for manufacturability using off-shelf hardware.
Context & Constraints
Context & Constraints
Pushrod double wishbone geometry inspired by modern F1 layouts
Designed around M3 fasteners and off-shelf RC shocks
Targeted compact packaging suitable for a sub-400 mm chassis
Intended as a mechanically accurate, physically manufacturable module
Design Reference
Design Reference
Modern F1 pushrod suspension layouts (Aston Martin AMR)
Interest in mechanically achieving variable ride height
Translating race-car suspension concepts into a compact, buildable module
Phase 1 – Geometry Exploration
Phase 1 – Geometry Exploration
Initial concepts focused on replicating visual geometry from reference images. This iteration revealed a lack of functional constraints with no defined attachment points or suspension travel.
Phase 2 – Functional Suspension Architecture
Phase 2 – Functional Suspension Architecture
The design was reworked into a true double-wishbone configuration with defined hinge points and pushrod attachment.
This established actual suspension motion but lacked damping and packaging for actuation.
Phase 3 – Final Active Suspension Assembly
Phase 3 – Final Active Suspension Assembly
The final design integrates off-shelf shocks and a servo driven rocker mechanism to enable active ride height adjustment while maintaining realistic suspension kinematics.
Engineering Decisions & Tradeoffs
Engineering Decisions & Tradeoffs
Chose off-shelf shocks over custom springs to reduce complexity and improve build realism
Accepted increased part count in exchange for modularity and serviceability
Designed hinge geometry around standard fasteners to enable future fabrication
Accepted simplified kinematics over full F1 compliance to maintain compact packaging and manufacturability
final motion study.mp4Validation and Motion
Validation and Motion
Motion studies were conducted to validate suspension travel, symmetry, and servo driven ride height actuation.
Motion studies were conducted to validate suspension travel, symmetry, and servo driven ride height actuation.
Maximum vertical wheel travel: 14 mm
Total module height: 50 mm
Shock compression: 11 mm (at full compression)
Effective motion ratio: 0.78 between wheel and shock compression
No interference detected at extreme positions
Assembly & Manufacturability
Assembly & Manufacturability
Parts designed with uniform hole sizing for M3 hardware
Chamfers added for printability and assembly clearance
Next steps include material selection, tolerance tuning, and physical prototyping
Exploded view used to validate part interfaces, fastener access, and modular assembly using standard M3 hardware
Fusion 360 · Mechanism design · Suspension kinematics · Assembly modeling · Design iteration
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