To replace a previously unoptimized front hub assembly on our 2WD vehicle, this project was designed to significantly reduce unsprung weight, resolve poor bearing fit tolerances, and build essential team expertise in CNC machining aluminum to drive our collective growth in becoming a competitive team. Over three major design iterations, the geometry evolved by thickening the hub flange, integrating structural ribs with larger fillets, and increasing the bearing and bore sizes to resolve excess bending stress. Evaluated under conservative loading conditions in a worst-case combined landing, turning, and braking scenario (~7kN vertical and ~4.3kN combined lateral), our final calculations and FEA simulations validated the design with a minimum Factor of Safety of 1.2. It was designed with DFM principles in mind across two setups on a 3 axis Haas CNC mill, allowing all outer profiling and a tight-tolerance (N7 interference fit) bearing bore to be completed in the first fixture before flipping and facing off sacrificial work-holding material, eliminating the need for high-precision re-alignment features.