Composite Chassis for SAE Formula - Inuition
Composite Chassis for SAE Formula - Inuition from Josh Williams
Composite Chassis for SAE Formula - Inuition

One of the most challenging parts of a mechanical engineer's curriculum at Iowa State is the Senior Design Capstone project. This is a team-based project class that tests students by requiring them to utilize everything they've been taught about engineering. My team and I worked with the Formula SAE team on our Capstone project during the spring semester of 2013. The goal of the project was to evaluate the potential use of a carbon fiber chassis design in future race cars instead of the traditional metal frame design they have been using for many years. Our team decided to split up tasks and assign people to become "experts" on one aspect of the project. I was in charge of evaluating the strength characteristics of the carbon fiber we would be using to create our new chassis. We also assigned a team leader, Kevin Riley, based on experience with working with FSAE and understanding their requirements. As a team, we experienced ups and downs, but made it through for a successful project.

This is the final CAD model created using the SolidWorks CAD package. It is based on the existing frame model that the SAE Formula team developed the year before.
I was responsible for evaluating the strength characteristics of the carbon fiber and supporting honeycomb structure that our sponsors donated. Shown here is the result of destructively testing a carbon fiber sample.
Our team decided to scale the project to 1/2 the size of the actual car to save on material costs. The model we developed uses a unique piece by piece construction and a rotisserie-style frame.
All the members of our group worked together throughout the project. Even after dividing up responsibilities our team members would take responsibility for every aspect of the project. Team members included Dallas Van Wyk, Jacob Lerdal, Kevin Riley, Pat Sanderson, Preston Gardner, and myself.
Once the mold was shaped and refined we wrapped it in carbon fiber layers using the rotisserie-style frame as support.
Then we wrapped the mold and carbon fiber in an airtight plastic wrap and pressurized the system creating even compression over the entire surface of the model. The wrapping procedure was not easy and required all hands on deck.
After baking in an oven under pressure the model hardened and cured. Once cool, we unwrapped to reveal the the final model.
Our project was unique because it was sponsored by the Formula SAE team. They could not match the usual $1,000 mark that most senior design teams receive and the materials and facilities required for this project were very expensive. Therefore, our team had the extra requirement of seeking and securing outside sponsorship. Thank you to our sponsors!
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Composite Chassis for SAE Formula - Inuition

One of the most challenging parts of a mechanical engineer's curriculum at Iowa State is the Senior Design Capstone project. This is a team-based project class that tests students by requiring them to utilize everything they've been taught about engineering. My team and I worked with the Formula SAE team on our Capstone project during the spring semester of 2013. The goal of the project was to evaluate the potential use of a carbon fiber chassis design in future race cars instead of the traditional metal frame design they have been using for many years. Our team decided to split up tasks and assign people to become "experts" on one aspect of the project. I was in charge of evaluating the strength characteristics of the carbon fiber we would be using to create our new chassis. We also assigned a team leader, Kevin Riley, based on experience with working with FSAE and understanding their requirements. As a team, we experienced ups and downs, but made it through for a successful project.

Josh Williams
Ames, IA