Managing design variants in Formula Student race cars : a digital engineering approach across multiple teams

Abstract

Increasing product complexity, shorter development cycles and cross-domain integration demands pose significant challenges for modern race car engineering teams. In Formula Student teams, heterogeneous toolchains, manual data exchange, late system integration, and high personnel turnover hinder efficient collaborative development and lead to repeated knowledge loss. This paper presents an integrated digital-engineering framework combining graph-based design languages (GBDL), model-to-text transformations, natural-language interactions via Large Language Models (LLMs), and Git-based version control to address these issues. By formalizing design knowledge and storing it in a centralized design graph, the framework ensures digital consistency of data and models, supports automated vehicle design variant generation, and enables seamless cross-domain integration. Through case studies of three Formula Student teams, the methodology demonstrates quantifiable reductions in design iteration time, enabling the evaluation of more than 10 4 suspension variants within days instead of a few dozen manually created variants, while reducing hands-on engineering effort from minutes per variant to a largely unattended optimization process. The results indicate that the approach not only enhances efficiency and collaboration but also preserves design knowledge for long-term knowledge management and reuse. Looking forward, this methodology provides a scalable route toward further engineering automation, systematic variant-driven development, and early-stage design optimization supported by design languages and integrated downstream toolchains.Ministry of Science, Research and Arts of the Federal State of Baden-Württember