FSAE Chassis

Technical specifications met by the computer design and the physical fabricated chassis (with partial triangulation.)

For my senior thesis, I designed, simulated, fabricated, and tested a tubular space frame chassis for Harvard’s first Formula SAE (FSAE) vehicle. This project establishes the foundation for Harvard's future participation in national motorsports competitions and supports continued work by the Harvard Undergraduate Automotive Society (HUAS).

The objectives for this project were to achieve competitive torsional stiffness, a spacious design to allow for future repairs and ease part installations, all while adhering to a strict $500 budget, and a book worth of rules from the SAE organization.

I began the project by using the simplest of chassis designs, ignoring the SAE rules for the first iteration and simply creating the main components as a sketch. After this, the sketch was recreated in Solidworks, I introduced rules and design characteristics iteration after iteration. I ended up creating over 70 CAD models to ensure the chassis design had a competitive structural rigidity and low weight. Each iteration underwent finite element analysis, allowing me to validate target specifications before beginning fabrication.

Once the CAD simulations were complete and all specifications were met as desired, I continued on to the fabrication of the chassis, using TIG welding. I fabricated key frame sections of the chassis using creative jigging (and uncomfortable welding positions) to create the main components of the chassis, after this, I just added triangulation members and tabs.

I created dozens of CAD templates, reference geometries, step-by-step guides to help the current team recreate or continue the work done on the FSAE chassis and suspension. My work established the first HUAS functional chassis - a launchpad for the student club to continue designing subsystems like drivetrain, cooling, aerodynamics, etc.

By completing this chassis, I not only met performance and budgetary goals but also provided tangible infrastructure for future teams. Going forward, the project paves the way for subsystem integration, while enabling me to mentor incoming HUAS members in fabrication techniques and FSAE practices and research.

FSAE Chassis

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Fabrication Solidworks (CAD)

Iterative Design Process Project Management