Chalmers Formula Student is a university team from Sweden that builds and races an electric car each year in the Formula Student competition. During races, the car’s electric motor generates significant heat, managed using a water cooling jacket, a component that wraps around the motor and carries coolant through internal channels to draw heat away. The team‘s earlier design worked but needed better thermal performance under peak loads.
Using ToffeeX‘s physics-driven generative design platform, the team ran thermal simulations and generated a family of designs reflecting different trade-offs between cooling performance and pressure drop, selecting a balanced design for manufacturing. The geometry was also adapted for 3D printing, without added support structures. The project reflects how simulation-driven design tools can support component-level thermal optimization within tight development timelines.
Image generated by: ChatGPT
