SAE Formula EV

Electric Vehicle

I support the FSAE Electric Vehicle team at NCSU to build and test NCSU's first Electric FV. I also design and build electronic packaging components and machine chassis and suspension components.

Cascadiamotion Motor controller

Rinehart PM 150 DZ

EMRAX 228 Motor

Steering wheel display assembly

I designed and build the display assembly for the steering wheel using PTC Creo and rapid prototype a design.

I imported the steering wheel and design used assembly level references. This allows for overall complete design and design check of interface and fitment.

I 3d printed a prototype using my own Tevo Tornado printer with Cura software and 0.2mm nozzle with slower print speeds to produce high quality prints.

Once the geometry was confirm, waterjet carbon fiber sheet using protomax

Connector face plate

DTM--04 cover

Accumulator Carrying handles

S: Formula SAE 2021-2022

T: Make handles that will carry the accumulator by yesterday, for servicing. The Accumulator weight ~130 lb

A: Using thick material and mounting holes as reference, handles were fabricated by the end of the night.

R: Carrying handles work well. No analysis was done but solution works well.

Milling and machining

I operated a manual milling machining and machine shop equipment in milling suspension clevis and jigs for chassis components.

part being fabricated is a suspension pick up point.

Composite Carbon Fiber

I helped lay the carbon fiber aero components using the vacuum bag method. Laying the carbon fiber on tooling board and with perforated and absorb-mat.

Once cured the part where then cut to final dimension then fitted with internal structural aluminum "fishes" then boned.

Procurment of Sponorship

HBFuller

I secured a new product sponsor for FSAE EV.

S; 2022 NCSU FSAE EV

T; We need to encapsulate the battery cell with a NHV material.

A; I research EV battery encapsulation solutions and came across HB fuller on a Youtube at a trade show. Their product was the perfect solution. 1/5 the way of epoxy and specialized in thermal propagation protection. I reached out to their contact us page.

R; I brought onboard a new sponsor that excels in EV products. We utilized there EV 4006 foam product.

Blicke

Setting: FSAE EV 2021-2022

Task: FSAE EV needs a accumulator cart for events that always had brakes on.

Action: I research online for casters and wheels design with Deadman switch features. I found Caster Connection which lead me to Blicke Casters. I reached out for a sponsorship and received $750 product sponsorship.

Result: The accumulator cart is currently being build. the switch will be activated by a dual brake lever.

Cable lead holder

The team was looking for a custom cable lead holder. I designed using PTC Creo sheetmetal and cable holder dimensions. I had the part waterjets and braked into shape.

Engineering Drawings

3D printing

For the Electric vehicle a energy capturing device is required to install on each vehicle, but parts aren't given to team until competition day. Using past data and model. A sample piece is 3D printed in preparation for placement, to avoid part interface.

Using a Strasys FM150 and GrabCAD software the sample part was printed in 3 hours.

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