My Experience

Steering Wheel

• Evaluated the 2024 steering wheel design and identified areas of unnecessary mass through CAD review.
• Conducted FEA simulations under a 600 N load to assess stress, strain, and displacement behavior across the wheel structure.
• Optimized the steering wheel geometry by removing low-stress material, achieving a 12.42% mass reduction without compromising strength.
• Collaborated with the team lead to validate simulation results and prepare the design for the upcoming manufacturing phase.

Front Suspension Control Arms

• Researched and conceptualized design ideas for suspension system concepts to improve the previous year’s design.
• Analyzed allowable loads on fixture points with FEA simulations to compare performance between straight and bent control arms.
• Remodeled the upper front control arms with SolidWorks CAD design tools.
• Manufactured and assembled suspension parts using machining processes including fixturing, cutting, drilling, turning, and surface finishing.
• Presented findings to club executives and team leads.

Brake Pedal Prototype

• Conceptualized and sketched design ideas for a brake pedal to achieve optimal performance while maintaining a balance between mass and size.
• Analyzed allowable loads on hard points with FEA simulations to compare performance across different brake pedal concepts.
• Developed an evaluation matrix to optimize design by reducing mass from 0.55 kg to 0.44 kg, minimizing size, selecting 1045 low-carbon steel, and achieving a target cost of $150–$200.
• Designed and modeled multiple brake pedal concepts in SolidWorks to evaluate and compare alternatives for best decisions.
• 3D-printed CAD designs and assembled the brake pedal; presented prototype findings to team captains and professors.

Ankle Joint connections

• Analyzed the 2024 ankle joint design to identify bulk, motion restrictions, and stress-prone areas.
• Redesigned geometry to improve natural ankle roll and stability on uneven terrain while reducing weight.
• Reinforced high-stress regions and redistributed material to prevent brittle failure in 3D-printed components.

Buckle and Strap System

• Evaluated the previous rubber strap system and identified inefficiencies in don/doff speed and tension reliability.
• Developed a new quick-release buckle mechanism paired with a firmer strap material for improved security and comfort.
• Integrated redesigned attachment points to enhance fit consistency and reduce unwanted pilot movement during tasks.

• Organized educational labs to teach children about physics, light, and sound.
• Encouraged active learning by bringing children to student exhibits at Science World.
• Communicated with camp manager, camp leaders, volunteers, and parents to ensure smooth camp operations.

• Designed the differential gear using SolidWorks with 3D engineering drawing references.
• Communicated with team lead and teammates to align on design decisions.
• Participated in team meetings to report on progress and next steps.