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This study explores the feasibility of designing and prototyping a customized automotive wheel rim by leveraging a suite of Industry 4.0 tools, including reverse engineering (RE), computer-aided design (CAD), finite element analysis (FEA), and topology optimization (TO). Commencing with a commercial wheel rim (Rota Wheels GRA 18”), a high-fidelity digital replica was acquired using structured light 3D scanning. Subsequently, a reverse engineering process was employed to generate a parametric base CAD model, from which a novel redesign was proposed. The structural integrity of both the baseline and redesigned models was computationally evaluated using FEA under loading conditions stipulated by the ECE R124 homologation regulation, comparing common aluminum (SAE 356) and advanced titanium (Ti6Al4V) alloys. Finally, topology optimization was applied to explore further lightweighting potential, and additive manufacturing (AM) process considerations were conceptually simulated. The integrated digital workflow demonstrated significant potential as a pathway for the rapid customization and performance enhancement of complex automotive components, although experimental validation and thorough economic analysis regarding advanced material selection and AM implementation remain essential next steps.

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Automotive Wheel Rim Prototyping Using Reverse Engineering and Computer-Aided Design Within the Industry 4.0 Context

  • 会议论文

  • 发表日期：

    2026年

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  • Gaizka Erkizia,
  • Xabier Garikano,
  • Mikel Iturrate,
  • Mikel Jauregi,
  • Eneko Solaberrieta,
  • Olatz Etxaniz,
  • Xabier Amezua

摘要

This study explores the feasibility of designing and prototyping a customized automotive wheel rim by leveraging a suite of Industry 4.0 tools, including reverse engineering (RE), computer-aided design (CAD), finite element analysis (FEA), and topology optimization (TO). Commencing with a commercial wheel rim (Rota Wheels GRA 18”), a high-fidelity digital replica was acquired using structured light 3D scanning. Subsequently, a reverse engineering process was employed to generate a parametric base CAD model, from which a novel redesign was proposed. The structural integrity of both the baseline and redesigned models was computationally evaluated using FEA under loading conditions stipulated by the ECE R124 homologation regulation, comparing common aluminum (SAE 356) and advanced titanium (Ti6Al4V) alloys. Finally, topology optimization was applied to explore further lightweighting potential, and additive manufacturing (AM) process considerations were conceptually simulated. The integrated digital workflow demonstrated significant potential as a pathway for the rapid customization and performance enhancement of complex automotive components, although experimental validation and thorough economic analysis regarding advanced material selection and AM implementation remain essential next steps.