Formula SAE I've worked on quite a few manufacturing, design and testing projects during my 4 years on Formula SAE. This page highlights some of the projects I've worked on. Hover over the images to learn more.

Driveshaft Safety Cage

This safety cage was fabricated to constrain the driveshaft coupling our engine to the dynamometer in case of failure. It was cut with an Oxy-Acetylene torch and TIG welded.

Dynamometer Engine Stand

I manufactured an engine stand which fixtures our new Yamaha R6 engine in the dynamometer for calibrations. Proper jigging and dimensional accuracy was critical to minimize misalignment of the output shaft.

PCB Design

I designed multiple PCBs in EAGLE for vehicle and testing use. I redesigned the vehicle's gear control module, transitioning from a PIC18 to a PIC32 microcontroller and implementing additional I/O for more robust paddle shifting functionality. Additionally, I designed a board to break out the engine control unit wiring harness for diagnostics and developmental wiring changes.

R6 Fuel System

I specified and implemented a brand new return style fuel system which would meet fuel delivery requirements for the new Yamaha engine. This included appropriate injector and regulator sizing, sensor selection, and a more robust fuel system in the dynamometer.

Engine Silencer

I designed and manufactured an innovative exhaust silencer to meet Formula SAE sound testing requirements. The design was improved through multiple iterations and performed well below the maximum sound level.

Dry Sump Reservoir

I led a redesign of the Dry Sump reservoir, which had been newly implemented in the previous year. I also forged new manufacturing partnerships to produce the component. The new design provided more consistent lubrication as opposed to the previous design.

Engine Rebuilds

I assisted in complete engine rebuilds for use in our racecar. This included teardown, sizing of bearings and other wear items, and full reassembly to specification.

Computational Fluid Dynamics

While most of my work has involved the engine system, I've also worked on some projects with other subsystems. For example, I ran CFD simulation using Star-CCM+ to assist the Aerodynamics team in diffuser design trade studies. I've also worked to start a simulations group within engine team, focused on validation of components critical to airflow.

Suspension Toe & Camber Brackets

I've worked on various machining projects with other subsystems. For example, I helped manufacture suspension Toe and Camber brackets using a Bridgeport vertical mill.

Gas Pedal

The gas pedal for our car was manufactured from carbon composite with aluminum and bronze bushings to pivot about. I also updated the design to integrate an accelerator pedal position sensor, accomodating a transition to electronic throttle control.

A new foundation

As my Senior Design capstone project, I successfully led the team in its transition to a new engine, marking one of the largest powertrain changes in team history. The team had used the Honda CBR 600 F4i engine as its powerplant for over a decade, and even prior to that, its carbureted ancestor had been used. Between dwindling parts supply and reliability concerns, the Honda engine was beginning to show its age. After much careful deliberation, it was elected to upgrade to the modern Yamaha YZF-R6 engine.

A complex problem

This change marked one of the largest changes to the vehicle's design in recent memory, and I was responsible for all aspects of the transition. The new engine package required not only mechanical integration, but also hundreds of hours of calibration, testing and validation. Almost every engine system component required some sort of modification to support the R6 powertrain.

Hard work pays off

The change proved to be enormously successful, resulting in one of the best competition seasons in team history. All design targets were met, with a noticeable increase in peak power. The new system was judged as one of the best designed powertrains at competition, even when competing against teams that had many years of development in their calibration and components. The vehicle completed the endurance event at all competitions attended, proving the reliability of the system. Engine performance was clearly demonstrated, with a 6th place autocross finish out of 115 cars at Formula SAE Michigan and a 3rd place autocross finish out of 80 cars at Formula SAE Lincoln.

Engine Calibrations

Hundreds of hours were spent in the engine dynamometer, calibrating various performance parameters.

The finished product

All the powertrain systems cleanly integrated into the vehicle.

At the track

The vehicle's performance was fine tuned at the racetrack, based on driver feedback and telemetry data.

Design

All components were designed in CAD, down to the nut and bolt.