Felicia Lee
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Following the design process from start to finish.
CMR is a high-ranking student-led Formula SAE racing team with aggressive goals for reducing mass. This year, for the sake of pushing for an even faster car, reducing weight is critical. By endeavoring design changes to wheel 25E such as introducing cutouts, reducing buttons, and switching 3D printing material, I align my design goals with those of the team.
3D modeling the steering wheel using SolidWorks. Communicating with engineer students working on the steering column, electric package, chassis structure design, and with drivers for ergonomics. My main goals were to cut weight, optimize the form, and maximize driver performance.
This wheel will be used for 25e (CMR’s 2025 all-electric race car).
Initial sketches and Solidworks models:
Prototypes and testing:
This process so far has been a huge learning experience for me, starting with self-teaching SolidWorks and understanding the limits of the physical materials. With the team’s switch from wet layups to prepreg (two different processes for manufacturing carbon fiber parts), I adjusted my own manufacturing plans to allow enough time for testing materials. Between low vacuum pressures, delaminations, and a finicky waterjet, I pivoted to a stronger schedule, used film adhesive, and began cutting with a router.
Final layup timelapse:
I forgot to add the film adhesive (the material that ensures the nomex core sticks to the carbon fiber) so I carefully dismantled the layers to insert it before I put the layup into the oven. The oven heats the pre-preg carbon fiber following a predetermined temperature path so that the resin cures properly.
Checking wheel positioning on the car:
In Action!
Learning Keyshot:
Latest update (April 2):
Working on paddle redesign after driver feedback.