Stanford Solar Car Project
Stanford Solar Car Project
Mechanical Engineer - June 2020 - June 2021
Mechanical Engineer - June 2020 - June 2021
My Roles
My Roles
For context, The Stanford Solar Car Project is a student-run organization at Stanford University focused on designing, building, and racing solar-powered vehicles. These vehicles are powered entirely by sunlight, utilizing solar panels on the top surface of the vehicle to generate electricity to drive the car's motor. The project goal is to build the most efficient vehicle possible to win the World Solar Challenge.
My two projects were:
Designed suspension knuckle that connects all suspension elements to the wheel and motor. Utilized Generative Design and FEA to inform design approach. Worked with manufacturers to arrive at an easily manufacturable part.
Designed aerodynamic wheel shroud. Used Fusion Modal Analysis and FEA simulations to ensure the part won’t interfere with other suspension elements during any maneuvers or as a result of vibration caused by the road and motors.
For context, The Stanford Solar Car Project is a student-run organization at Stanford University focused on designing, building, and racing solar-powered vehicles. These vehicles are powered entirely by sunlight, utilizing solar panels on the top surface of the vehicle to generate electricity to drive the car's motor. The project goal is to build the most efficient vehicle possible to win the World Solar Challenge.
My two projects were:
Designed suspension knuckle that connects all suspension elements to the wheel and motor. Utilized Generative Design and FEA to inform design approach. Worked with manufacturers to arrive at an easily manufacturable part.
Designed aerodynamic wheel shroud. Used Fusion Modal Analysis and FEA simulations to ensure the part won’t interfere with other suspension elements during any maneuvers or as a result of vibration caused by the road and motors.
Suspension Knuckle
Suspension Knuckle
Wheel Shroud
Wheel Shroud
This knuckle connects the wheel to both control arms, the shock, the steering rod, the brakes, and the wheel shroud.
The goal in designing this piece was to minimize weight while incorporating all of the necessary connection points and meeting all race guidelines for FOS.
This knuckle connects the wheel to both control arms, the shock, the steering rod, the brakes, and the wheel shroud.
The goal in designing this piece was to minimize weight while incorporating all of the necessary connection points and meeting all race guidelines for FOS.
This carbon fiber and sandwich panel wheel cover reduces the volume of air that the spinning tire interacts with which significantly reduces the drag on the car.
Due to a failure in the previous design cycle, the main design constraint was ensuring vibration experienced while driving would not cause the wheel shroud to break or interfere with other parts of the suspension system.
Given the hard points locations and forces at each location I used Fusion Generative Design to understand what the shape of the optimal unconstrained design is. I then worked with members of the Autodesk team, our manufacturers, to make the part manufacturable. I simplified the complex generative design based part shown above as I reduced manufacturing cost and eventually arrived at the final part that resembls an I-Beam in structure. Countless simulations, MATLAB force calculating scripts, and load cases informed the design. The other dominant design constraint was interaction with all other suspension parts. Ensuring no parts would interfere during any meaneuver was a key design goal.
Given the hard points locations and forces at each location I used Fusion Generative Design to understand what the shape of the optimal unconstrained design is. I then worked with members of the Autodesk team, our manufacturers, to make the part manufacturable. I simplified the complex generative design based part shown above as I reduced manufacturing cost and eventually arrived at the final part that resembls an I-Beam in structure. Countless simulations, MATLAB force calculating scripts, and load cases informed the design. The other dominant design constraint was interaction with all other suspension parts. Ensuring no parts would interfere during any meaneuver was a key design goal.
I approached this design with a combination of Fusion Modal Analysis and FEA simulations of the forces felt by the car during its most extreme maneuvers. By varying sandwich panel thicknesses in specific regions and modifying attachment points the design objectives were met.
I also designed the molds for the carbon fiber wet layup construction, shown below.
Decided to use wingnuts with lock tight to attach the two halves of the shell after researching options varying from complex locking mechanisms to magnets.
I approached this design with a combination of Fusion Modal Analysis and FEA simulations of the forces felt by the car during its most extreme maneuvers. By varying sandwich panel thicknesses in specific regions and modifying attachment points the design objectives were met.
I also designed the molds for the carbon fiber wet layup construction, shown below.
Decided to use wingnuts with lock tight to attach the two halves of the shell after researching options varying from complex locking mechanisms to magnets.
This carbon fiber and sandwich panel wheel cover reduces the volume of air that the spinning tire interacts with which significantly reduces the drag on the car.
Due to a failure in the previous design cycle, the main design constraint was ensuring vibration experienced while driving would not cause the wheel shroud to break or interfere with other parts of the suspension system.
Final Product
Final Product
Full integration of both parts with suspension joints, shock, brake, and wheel.
Full integration of both parts with suspension joints, shock, brake, and wheel.
Additional Photos
Additional Photos
Additional photos of Suspension Knuckle.
Additional photos of Suspension Knuckle.
Shroud adjustment for rear wheel. Different integration to fit rear suspension and motor.
Shroud adjustment for rear wheel. Different integration to fit rear suspension and motor.
Half of the mold for the carbon fiber wet layup.
Half of the mold for the carbon fiber wet layup.