Suspension Design for Surya
As Engineering Director at Buckeye Solar Racing I led the ground-up redesign of the front and rear suspension after the existing geometry proved to be incompatible with the other vehicle components. My role involved mentoring, CAD modeling, material selection, and manufacturing planning.
Starting Off
Once we realized the existing suspension design couldn’t be integrated with the remainder of the vehicle, I began working alongside our suspension lead to get the redesign completed. After she completed the kinematic modeling, it was handed off to me to lead the mechanical component design.
This process included determining how best to design each part for ease of manufacturing, providing guidance to underclassmen in CAD modeling practices, and sourcing the materials that would be used in the suspension’s construction.
Manufacturing
Once we had our design nailed down, I led the manufacturing and fabrication of the suspension. Working in conjunction with the team’s suspension lead, I utilized MasterCAM to create the g-code for CNCing various components.
Leading the team’s underclassmen, I instructed them in the use of the manual mill and helped to machine the parts of the suspension. I was then also responsible for the welding of the control arms as well as the various mounting points on the chassis of the vehicle.
Results and Lessons Learned
Under my guidance, the team was successfully able to complete the suspension re-design and manufacturing in time for our goal of a rolling chassis by summer.
It served as a valuable learning experience in how best to manage a small team when facing hard deadlines. I was able to hone my fabrications skills as well as learn more about teaching others how to fabricate components.
