As a member of the Chassis sub-team, the goal was to design and manufacture a space frame chassis that serves as the backbone of the vehicle and houses all the components. Additionally, I had to ensure that the design complies with all SAE rules and regulations. This role provided a thorough understanding of vehicle dynamics, manufacturing, and vehicle systems (aerodynamics, drivetrain, suspension, and steering).

The chassis was manufactured with 4130 steel. The tube profiling and bends were outsourced to a professional company. I designed a jig on a surface welding table to provide a rigid framing structure. It took 4.5 weeks for the chassis to be completely manufactured, not including design time. The design process is highlighted below.

I continuously strived to increase vehicle drivability by achieving chassis performance targets to increase the stiffness to weight ratio. The chassis model would be designed in SolidWorks and then iteratively updated by analyzing ANSYS FEA results. Finally, the FEA results would be validated through physical torsion testing. We would take the previous chassis and weld on the proposed changes and compare the deflection with respect to the torque applied.

​This design process allowed me to achieve a 68% increase in stiffness with only a 3% increase in weight. Torsional stiffness: 1431 Nm/Deg to 2409 Nm/Deg and mass: 61.3 lbs to 63.4 lbs.​

To introduce further upgrades to the chassis, I performed studies on ergonomics to ensure the driver’s seating position was comfortable with sufficient visibility. Additionally, I tested how the driver position affected the center of mass and vehicle dynamics. This was all achieved by building jigs out of wood and recording several measurements. These measurements played a crucial role in the steering wheel, and pedal box position and influenced the seat design.