top of page

FORMULA SAE

Throughout my college years, I collaborated on three complete Formula SAE vehicles, culminating with being Team Leader and using FSAE as my senior project. Besides all the fun and excitement, Formula SAE is a large undertaking which provided me with immense experience in design, fabrication, prototyping, and team work. Below is some of the work completed on my senior  vehicle.

DESIGN RESPONSIBLITIES

Besides Team Leader, I was the lead designer responsible for the general vehicle layout, as well as component design of many parts including the frame, drivetrain, and intake.

framedesign.png

The frame design was made with a focus on simplicity of fabrication. This had to meet all the requirements such as crash safety in regards to rollover and side impacts, and fit a 95th percentile male. The final optimized frame had a weight of 93lbs.

Frame Design

diffdesign.png

The drivetrain needed to take the chain drive from the Yamaha R6 motor and turn it into a 2-wheel drive LSD. The mounting system for the differential needed to be in perfect alignment with the rear suspension, strong enough to handle turning and drive forces and needed a way to tighten the chain. Focus was once again on simplicity, by using mostly sheet and standard shapes to make the 3D shape as well as use gravity for ideal tightening.

Differential Design

intake.png

Intake Design

The intake was the main area where performance of the engine could be won or lost. The rules stated that all intake must be through one throttle and a 20mm diameter restrictor. As such, the restrictor tube was heavily simulated. The intake manifold was designed to encompass as large a volume as possible for optimal power after the restriction. The main body was designed as two carbon fiber reinforced 3D printed halves. At the time, it was the largest 3D print ever made at the school.

FABRICATION

Below are various pictures of the build process. Most of the components were hand made using many different types of materials, tools, machinery, and techniques.

THE CAR

Vehicle Specs:

  • Horsepower: 101 HP​

  • Redline: 12,000 RPM

  • Top Speed: +105 MPH

  • Weight: 547lbs

  • Weight Distribution: 46:54​

bottom of page