o Led a department of 10 members to ideate, design, validate and assemble a complete race car assembly with focus on reliability
o Implemented Topology Optimization for manufacture of various parts such as Brake callipers to reduce weight by 40% in comparison to the stock calliper
o Led the team to a 15th place in Engineering Design event at Formula Student Germany 2019, scoring 100/150 points
o Won the BASF Best use of 3D printing award at Formula Student Germany 2019 while presenting the custom-made steering wheel for the car
o Led a department of 6 members to improve driver response time and driver comfort – achieved a more responsive car according to driver feedback
o Designed and manufactured a carbon-fibre based seat according to the largest driver impression and accommodated the other drivers using PU foam seat inserts
o Designed and manufactured a custom steering wheel with TPU based steering grips and ABS base paddle shifters to aid the driver during driving. This also included shifter lights and a screen for necessary information for the driver to manoeuvre the car
o Designed and analysed critical components such as hubs and uprights of wheel assembly using CAD and FEA software on the basis of Factor of Safety
o Designed the steering assembly for the car on the basis of inputs from Vehicle dynamics
o Validation of Tubular space frame using NDT methods and Torsion test
o Implemented DFAM principles when designing Data Logger box and Electrical Assembly box which were made from ABS material using FDM process
o Implemented DFMA principles on the design at multiple junctions, for example, DFA principle was applied in designing crank shafts for ease of assembly so that tools could reach the necessary access points
o Implemented FMEA principles while brainstorming for design. This helped in tackling potential pain points that might have occurred in future