Case Study / Formula Student
Selected Formula Student engineering work across driver controls, aerodynamics and suspension, combining CAD development with composite manufacturing, simulation and prototyping.
Selected work
The steering wheel was developed in Fusion 360, with mould tooling prepared in Creo. The design used a custom carbon-fiber front plate together with SLS 3D-printed PA components, with emphasis on a lightweight, ergonomic and modular assembly.
The front wing combined full carbon-fiber aerodynamic surfaces and a carbon-fiber spar with water-jet-cut aluminium ribs. CFD work in Simcenter STAR-CCM+ was completed before the final design, while Fusion 360 and Creo were used for CAD and mould development.
Carbon-fiber suspension control arms were designed in Fusion 360 and checked with FEM simulations to verify the components against the expected loads. The links used bonded metal rod-end inserts to connect the composite members into the suspension assembly.
Engineering approach
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