I designed a welding jig assembly for our school's Formula SAE team. 

With 10 primary jigging plates, 42 secondary plates, and 6 donut jigs, the design ensured that locating and jigging the tubes would be seamless and accurate. With manufacturability and ease of assembly in mind, all the aluminum extrusion joints are bolted together with surface plates. 

To ensure that the jigging had a balance in constraint (i.e., wasn't overconstrained/underconstrained), secondary jigging plates were installed to add accuracy. 

For further accuracy, critical nodes have a donut-shaped jig that is 3D-printed out of ABS.

For our Formula SAE team, I designed a fully triangulated chassis that optimized our vehicle dynamics, suspension geometry, and torsional rigidity. 

With space claims for our high-voltage battery and other low-voltage subsystems in mind, our chassis ensures that our vehicle will be able to run without structural issues.

Suspension geometry such as damper and bellcrank placements inspired our front-bulkhead support design. 

Through a statics study done on our chassis, I achieved a result of 2.23mm of displacement.

For a side-project, I decided to CAD a functioning front-wing package for our vehicle. Due to our priorities, this package will not be manufactured, and instead, remains as a model for future reference.

Featuring 189 Newtons of downforce, this front-wing design was one of four iterations that satisfied performance needs needed for events such as skidpad and autocross.

As part of our driver-ergonomics testing and rules compliance, I modeled a 95th percentile male, "Percy". The primary purpose of Percy was to verify space claims in the chassis and ensure that our current chassis was in compliance with the rulebook.

For driver ergonomics, this design incorporated ball-joint limbs to account for driver adjustability and preference.

For practice on a HAAS DM1 CNC Mill, I cut complex radii on square stock, resulting in a tape dispenser geometry. 

For this project, I did dry runs on the CNC, calculated tool-length offsets, edge-found datums, indicated vises for alignment, and input proper work offsets.

I heavily pushed myself to maintain tolerances of +/- 2 thousandths of an inch for all dimensions and features. Through manual metrology, almost all features and dimensions were within spec.