BeamNG.cad — From SolidWorks to a Tuned Vehicle

Problem

As our vehicle designs evolve, rebuilding a simulation by hand takes time and specialist knowledge. Student turnover makes that expertise difficult to retain. My goal is to make CAD-to-simulation preparation repeatable so future team members can continue using and improving the workflow.

Solution

I built a SolidWorks add-in in C#, supported by Python geometry, calibration, and vehicle-generation tools. It captures selected CAD components, material properties, and reviewed joint definitions, generates the BeamNG physics structure, connects the visible geometry, and packages the vehicle as a mod.

The workflow now covers the frame, suspension linkages, steering, wheels, drivetrain, and component mounts. Automated tests record vehicle motion and compare suspension behavior with the source CAD geometry, helping identify where the generated model needs refinement.

Current Milestone

The pipeline has progressed from importing a frame to producing a tuned vehicle that can be driven and evaluated in BeamNG.

• Complete vehicle generation and standalone mod packaging from reviewed CAD inputs.
• Repeated tests held 18, 36, and 54 km/h without broken beams or reported instability.
• Controlled suspension loading demonstrated recovery after release, providing measurable evidence alongside driving feedback.

Next Steps

I’m refining physical accuracy using measured shock and tire specifications, improving numerical mass and inertia, and extending validation to more demanding driving and impact conditions. The current build provides a working foundation for that development; correlation with the real vehicle remains ongoing.