Brown Formula Racing is Brown University’s student-led design and build team. Operating as a simulated engineering company, the team takes projects from concept to competition, giving members hands-on experience in CAD design, design for manufacture, metal and composite fabrication, and vehicle testing. The team welcomes students of all backgrounds, emphasizing practical learning and real-world engineering skills beyond the classroom.
Brown Formula Racing competes in Formula SAE Michigan, the largest and most prestigious Formula SAE competition in North America. University teams design, build, and race high-performance formula-style vehicles, evaluated through dynamic events and rigorous design, cost, and business reviews by industry experts.
For Brown Formula Racing, the wheel hubs are mission-critical components that must withstand massive cornering forces and braking torques. These parts must meet:
Beyond the technical requirements, the team faced additional constraints common to Formula SAE projects:
The team required more than a conventional machine shop. They needed a partner who excels in rapid prototyping for motorsports—someone capable of delivering race-grade precision and advanced 5-axis capability within the tight schedule.
The project required machining complex wheel flanges with extreme concentricity requirements and significant material removal, all while maintaining structural rigidity and surface integrity.
As a premier provider of precision CNC machining services for the automotive and racing industries, 3ERP specializes in turning complex engineering visions into high-performance realities.
To address these challenges, 3ERP developed a comprehensive machining strategy combining CNC turning, 5-axis milling, and custom fixturing, supported by in-process inspection.
For challenging internal pockets, a multi-step approach was applied:
This strategy ensured stable cutting and accurate feature geometry.
Inspection data is recorded for quality traceability and race compliance.
Watch how 3ERP machines the wheel hubs from solid 7075 aluminum using CNC turning and advanced 5-axis machining technology.
Rapid material removal and precision turning of outer diameters and end faces, achieving micron-level concentricity for high-speed rotation stability.
Accurate deep bore creation for wheel hub and locknut assembly, ensuring structural integrity and assembly reliability.
Fine internal diameter finishing to maintain strict tolerances and smooth mating surfaces for bearing alignment.
Thread cutting for wheel locknut connections, verified with thread gauges to guarantee fit and functional safety.
Thanks to 3ERP’s 5-axis machining capabilities, we’re able to push the limits on our uprights and wheel package designs for maximum performance.
