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Gears Mining Australia primarily designs massive equipment for the mining sector. Recently, they expanded their engineering scope to include high-performance racing engines. Chief Engineer Andrew Tuxford explained the immense challenges of this highly competitive market. Customers expect enormous power outputs, often demanding up to 2,500 horsepower from a single engine block.
At the same time, the racing market is extremely cost-sensitive. The engineering team cannot afford to build endless physical prototypes to see what breaks. Instead, they rely entirely on virtual models to evaluate torsional rigidity, combustion loads, and general deformation.
By testing main cap bolts and rod bolts in a digital environment, Gears successfully moved from computer-aided design directly to the machine shop and then straight to the race car. They skipped physical testing entirely. Within a two-week period, they iterated through more than ten different engine designs to find the optimal configuration.

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