Construction: steel tubing, aluminum sheet metal

CAD / Analysis Software: SolidWorks

In 2021, as a part of Northeastern University's Formula Electric Team, I took part in the Optimal Hybrid Design Challenge on the chassis redesign team.

The project challenged was put forth to see how teams could take their current fully electric or internal combustion engine (ICE) student formula cars and integrate a hybrid drive system.

My role focused on chassis development, necessitating significant updates to comply with regulations and accommodate the hybrid system. Key modifications included:

1. Hybrid Drive System Integration:

   • Added side pods for batteries and electronic components.

   • Extended the crash nose to create space for ICE integration.

2. Chassis Optimization for Weight Reduction:

   • Adjusted tubing wall thicknesses to reduce weight while meeting safety standards.

3. Safety Regulations Compliance:

   • Increased the roll hoop height for improved driver safety in rollover scenarios.

   • Designed side pods considering side impacts and fire safety.

Through these changes, we reduced the initial chassis's weight by over 100 lbs. After the addition of components like side pods, a taller roll hoop, and crash nose extensions, the final chassis weight was only marginally heavier than the previous version. 

After the competition was over, our team finished first overall in the design challenge and I'm proud to say I helped a bit to that win.

This was my first time working with SolidWorks and specific functions to design the tube frame, or even a simple weight analysis.

I was also very nervous presenting my 1 slide to the judges but we won so I think the practice was worth it.