Session: ASME Undergraduate Student Design Expo

Paper Number: 164989

Transforming Challenges Into Solutions: Lessons Learned in Composite Design for Formula Sae Electric Car 

Introduction: As a mechanical engineering major at Clarkson University, I have served as the composites lead for the inaugural Formula SAE electric team. I have led activities in designing, machining, prototyping and fulfilling other requirements for our team. This work contributed to building a Formula Electric SAE car to compete in racing seasons during my sophomore and junior year.  This experience has been critically important for building a foundation for the team’s future efforts. 

Methodology: I led efforts to produce an ergonomics package for the team’s first car, the 259, developed for the 2022-2023 racing season. Although we were unable to compete in the Michigan event, my primary responsibility involved designing the Impact Attenuator shroud and the nose cone. This task proved challenging, as our subteam underwent several design iterations and review cycles. Initially, we intended to use 3D splines in SolidWorks for the nose cone design; however, we had limited experience with surfacing modeling. Consequently, we shifted to a more aesthetically pleasing and structurally simpler design using guide curves with two open loops to create a lofted extrusion.

We then performed a kinematic analysis in SolidWorks but faced limitations and were unable to conduct fluid analysis in ANSYS due to our developing skills. However, no issues arose once the part was integrated into the car. After finalizing our design, we explored manufacturing methods. Due to resource constraints, we were unable to use high density tooling foam so we leveraged more readily available 3D printing equipment. We created both positive and negative molds, preparing them by sanding, applying Bondo, sanding again, and using multiple layers of release wax. Finally, we laid up our 3K weave carbon fiber in a quasi-isotropic configuration. Upon completing the bagging process—consisting of applying peel ply, breather, and bleeder cloth, encasing the mold in bagging film, and vacuum bagging—the positive mold was significantly easier to remove. Ultimately, the fitment of the nose cone onto the chassis, incorporating the impact attenuator, was relatively straightforward.

Conclusion: This project not only enhanced my practical skills and knowledge in composite materials and design but also fostered a collaborative team environment that emphasized learning and innovation. The experience gained from navigating challenges, experimenting with different design methodologies, and employing advanced manufacturing techniques has been invaluable. As we continue to refine our processes for future competitions, the insights gained from this endeavor will serve as a foundation for our team’s continued development and success in the realm of Formula SAE electric racing.

Presenting Author: Domenico Lupi Clarkson University

Presenting Author Biography: Domenico Lupi is a dedicated mechanical engineering student currently engaged as a Machine Shop Associate at the Clarkson University Research Prototyping Laboratory in Potsdam, NY. Since October 2021, he has taken on a leadership role in overseeing training for engineering students on essential shop skills, safety protocols, and operation of various machining equipment, including ACERs and CNC mills. His responsibilities also include participating in CAD/CAM software training utilizing SolidWorks and Mastercam, and applying component design and fabrication skills to support student engineering clubs, such as the Formula SAE Speed, Baja, Chem-E, and the snowmobile teams.


During the summer of 2023 and again in 2024, Domenico interned at General Dynamics Electric Boat in New London, CT, where he was involved in crucial engineering tasks for the recertification of the Virginia Block V attack submarines. With a strong foundation in mechanical engineering and hands-on experience in both academic and professional settings, Domenico is committed to innovation and collaboration in the field, aspiring to create impactful solutions in engineering and design.

Authors:

Domenico Lupi Clarkson University