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🏎️

Racing Speed

74 km/h

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Competition

Formula Hybrid

CAD

Design Tool

SolidWorks & AutoCAD

💧

Waterproof

IP Rating Tested

3D Printer

Material

PETG 3D Print

⚡

Integration

Full System

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🎯 Project Overview

As a member of the Waterloo Formula Electric team, I contributed to chassis design and structural development for the race car. My role focused on inserts machining, CAD modeling, and mechanical optimization.

I designed two key enclosure systems for the team: the driver dashboard enclosure and the electrical board enclosure, each designed with a focus on environmental protection, structure integrity, and system integration.

The team competes in Formula SAE Electric competitions, where we design, build, and race electric vehicles against universities from around the world. This experience provided hands-on engineering practice in a fast-paced, collaborative environment.

📸 Project Gallery

Browse through my key contributions to the Waterloo Formula Electric project, featuring two custom-designed enclosure systems.

🖥️ Dashboard Enclosure System

Complete redesign of the driver dashboard enclosure, from initial concept through testing to race implementation.

⚡ Electrical Board Enclosure System

Custom protective enclosure designed for the electrical board assembly, ensuring component safety and preventing damage from drops or impact.

⚡ Electrical Design Electrical Board Enclosure CAD Design

Electrical Board Enclosure - SolidWorks CAD

Custom-designed protective enclosure for electrical board assembly. Features integrated mounting points, cable management channels, and optimized geometry for component protection.

🔧 Modular Design Electrical Enclosure Bottom View

Bottom View - Modular Connection System

Bottom surface features innovative LEGO-style connection pieces for easy assembly and disassembly. This modular approach allows quick removal for maintenance and servicing without tools, improving serviceability during competitions.

⚡ My Contributions

🖥️ Dashboard Enclosure Design & Development

Worked on complete redesign and fabrication of the driver dashboard enclosure system.

  • Redesigned original dashboard enclosure in SolidWorks with improved button positioning and structural geometry
  • Implemented PETG 3D printing with integrated brass inserts for secure mounting and durability
  • Conducted waterproofing tests to validate IP rating for wet racing conditions
  • Performed mechanical stress testing including load validation
  • Successfully deployed in competitive racing environment at speeds up to 74 km/h

⚡ Electrical Board Enclosure Design

Designed protective enclosure system for critical electrical components.

  • Created custom CAD model in SolidWorks for electrical board protection
  • Integrated LEGO-style mounting points and cable management channels for clean wiring
  • Optimized geometry for component accessibility and prevented from damages
  • Collaborated with electrical team to meet all technical requirements

🔩 Machining & Manufacturing

Performed precision machining operations for vehicle components and mounting systems.

  • Operated mill, lathe, and waterjet cutter to fabricate mounting brackets, spacers, and chassis components
  • Machined aluminum and steel components with tight tolerances (±0.1mm) for proper fitment
  • Created threaded holes and mounting interfaces for enclosure and chassis assembly
  • Performed quality control measurements using calipers and micrometers to verify specifications

🚀 Engineering Journey

From concept to competition - here's how this project shaped my engineering expertise

01
CAD

Design & Modeling

SolidWorks CAD Engineering Specifications Assembly Modeling DFM Principles

💡 Key Insight: Learned that considering manufacturing constraints during the design phase prevents costly iterations and redesigns later in the process.

02
Machining

Fabrication & Machining

PETG 3D Printing CNC Machining Brass Insert Installation GD&T

💡 Key Insight: Hands-on machining experience revealed the importance of proper tool selection and setup - small adjustments make huge differences in final part quality.

03
Testing & Validating

Testing & Validation

Waterproof Testing Stress Analysis Iterative Refinement Quality Control

💡 Key Insight: Real-world testing uncovered seal design weaknesses that weren't apparent in CAD - iterative testing is essential for reliability.

04
System Integration

System Integration & Racing

Cross-Team Collaboration Electronics Integration Race Deployment 74 km/h Validation

💡 Key Insight: Early communication with the different teams prevented integration issues - collaborative planning saves time and ensures all systems work together seamlessly.