BMW M20
Crankshaft Optimisation
A factory E30 crankshaft, reengineered for high-rpm performance.
The original crankshaft from a BMW M20 engine was 3D scanned in collaboration with one of our partners. From the point cloud, a precise CAD model was built and the baseline weight calculated at 25 kilos. From there, a new counterweight profile was designed incorporating a knife edge geometry calculated specifically for this crank.
The execution is more precise than it sounds. Remove too much material and the crank loses structural rigidity. Leave too much and the rotating mass stays too high to safely reach the rpm levels the client was targeting, well beyond what the factory ever intended. Using 5-axis CNC milling by our machining partner, the designed profile was machined into the counterweights with the accuracy that margin requires.
The final weight came in at just under 20 kilos. Five kilos removed from a rotating assembly without compromising the structural integrity of the component.
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