In the world of collegiate motorsport, innovation isn’t optional, it’s the baseline for success. For MSOE’s Raider Racing Baja team, the 2025 competition season brought with it a clear goal: rethink the rear suspension architecture of their vehicle, Onyx, without compromising strength or reliability.

What they needed wasn’t just a supplier. They needed a collaborator who could bring advanced materials, engineering insight, and manufacturing speed to the table. That’s where we came in to the story.

To support Onyx’s redesigned load-bearing rear axle, MSOE needed a rear knuckle that could handle brutal dynamic loads while fitting into a tighter space within a custom drivetrain. Traditional machining simply couldn’t deliver the complex geometry required, especially not on a tight pre-race timeline.

MSOE’s design team turned to Evology to leverage Direct Metal Laser Sintering (DMLS) for a smarter, lighter, and more precise knuckle solution.

Evology supported the student engineers through the entire development process—offering guidance on materials (AlSi10Mg), print feasibility, and design for Additive Manufacturing. The results spoke for themselves:

• 312g final weight vs. 2,250g for traditional steel—an 86% weight reduction
• Fully integrated mounting features, eliminating excess hardware
• Improved camber control and better impact stress distribution
• Eliminated historical stress risers through continuous curvature design

Using advanced FEA simulations and Evology’s iterative production workflow, the team was able to refine and test multiple designs—all while staying on schedule.

Evology’s production environment allowed MSOE to move from CAD to printed parts in a matter of days—not weeks. This enabled rapid physical testing and real-time adjustments ahead of competition deadlines.

By using additive manufacturing intelligently, the team not only cut mass but also improved durability and suspension articulation under race conditions.

Evology Manufacturing supports student innovation with the same focus and rigor we bring to aerospace, defense, and medical projects. Because when precision meets performance, engineering wins.