Realistic Measruements Solidworks 25' Bulls Racing FSAE

Precision Welding Fixtures -FSAE Chassis

Sebastian Carias · Jan-Feb 2026

Project Description: Designed and implemented custom welding fixtures and alignment systems for a Formula SAE race car chassis to ensure precise positioning during fabrication. Developed 3D-printed spacers to maintain steering rack alignment, improving steering accuracy and reducing post-weld corrections.

Role & Contributions

Designed and developed a suite of welding jigs, fixtures, and alignment tooling in SolidWorks to support chassis fabrication for the FSAE vehicle. Engineered 3D-printed alignment spacers specifically for steering rack centering, translating geometric tolerancing requirements directly into manufacturable part geometry. Identified and resolved real-time alignment challenges during live welding operations, applying iterative design thinking to ensure tooling remained effective under fabrication conditions.

Motivation

Dimensional accuracy during chassis welding is not a convenience — it is a structural and performance requirement. In an FSAE context, even minor misalignment in the steering rack mounting position can propagate into Ackermann geometry errors, inconsistent toe behavior, and unpredictable vehicle response at the limit. Rework after welding is time-costly and risks introducing residual stress into the chassis. This project was motivated by the need to eliminate alignment variability at the source, building repeatable, low-cost tooling that could be deployed consistently across fabrication cycles without relying on operator judgment alone.

Technical Details

CAD Platform: SolidWorks (jig and fixture geometry, spacer design)
Manufacturing Method: FDM 3D printing (PLA/ABS), selected for rapid iteration and low tooling cost
Design Constraints: Alignment precision to steering geometry tolerances, thermal resilience under welding heat exposure, ease of installation and removal during assembly, and repeatability across multiple fabrication runs

Results & Evaluation

Tooling successfully improved alignment consistency during welding operations, reducing reliance on manual positioning and minimizing the incidence of post-weld corrections. The 3D-printed spacers enabled repeatable steering rack centering across chassis builds, directly supporting geometry accuracy and reducing rework time. The project demonstrated that low-cost additive manufacturing, when properly designed and toleranced, can serve as a legitimate fabrication aid in a competitive motorsport environment — and reinforced practical skills in design-for-manufacture, geometric constraint analysis, and the integration of CAD intent with shop-floor reality.

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