pic: 5 Inch Wheel

[RMS11]

I first cut out 5 spokes that went fully from the center to the outside with all inside material cut out. I made them 1/4 inch because I felt that to be plenty to support the wheel. I filletted the edges of the spokes for extra support and thev used cosmosxpress in solidworks to run stress analysis, placing an 120 lb force on an individual wheel supported by the axle. Then after seeing it would not break I cut more weight by adding holes in an artsy way and did more stress analysis. Really I find the best way to make light weight objects is to cut a little weight and then stress test and repete until you are either happy with the weight or unhappy with how strong it is getting.