UWFE - Other Projects

Throughout my time with UWFE I have been involved with the Chassis, Driveline and Tractive subteams. Some of the cool projects I had the opportunity to work on were:

• Optimization and lightweighting of motor output shaft and stub shafts using ANSYS Mechanical. Reduced weight by 43% compared to past year's output shaft.

• Designed, simulated, and machining an aluminum enclosure for a status indicator light. The enclosure acts as a heatsink, so I had to consider thermal management (which was simulated in ANSYS Mechanical), electrical insulation and waterproofing. DFM was very important as the part was to be manually machined, including a precise groove for a gasket.

• Design of a dynamometer fixture for our motor, concentric within 0.005" of the dynamometer. We conducted a FEA study to ensure the motor mount would withstand the peak motor torque.

• Designing a carbon fiber fan shroud, designing the 3D printed mould, printing the mould, and manufacturing and finishing the shroud following the team's strict layup procedure. It was extremely rewarding to be able to follow the part from conception to real life.

• Machining components for our custom limited-slip differential to 0.05mm (0.002") tolerances

• Designed and 3D printed jigs for welding motor guard tabs to the chassis