UW Formula SAE
Project Lead
Design | Analysis | Manufacturing
Racecars...
Teams Manufacturing | Drivers
Tools SolidWorks | Ansys | Mills & Lathes | Prepreg
Formula SAE is a class of racecars designed, built, and competed with by Universities around the world.
With 10 weeks to design, 10 weeks to manufacture, and 10 weeks to test, each member owns at least one project. For me, that meant a pedal tray assembly, roll hoop, and the manufacturing of a carbon fiber chassis.
Design
Competitions are hosted worldwide and judged on criteria ranging from lap times to business justifications. As a top US team, UW expects the highest standard in every aspect. The most design-heavy project of the pedal tray had to
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Provide brake and throttle mounting/control
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Be ergonomic for a variety of drivers
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Pass safety critical rules & regulations
Hand Calcs | Design Intent
Build
10 weeks to manufacture, test, and assemble onto the final car.
The pedal tray required a complete redesign week 9 due to interference with a newly-repositioned steering rack. This meant removing adjustability and focusing on lightness & robustness. As for manufacturing the carbon fiber chassis, there is just no replacing 100s of hours of hand-time dedicated to prepreg/wet layups and hand sanding.
Sticky Mold | Polished Chassis