Brakes Design
As a Usability design lead for UR Baja SAE I was responsible for the 2018 and 2019 braking system, drivers to car integration and safety. With the Usability team, we designed and modeled various components in Solidworks, focusing on an iterative design approach to optimize the pieces for weight, performance, manufacturing capability, and cost. All designed pieces were saved as Parasolid files to then create Finite Element Models and simulations in Siemens NX/Nastran. Designed components were run through a Finite Element Analysis to validate the design. I worked with other subsystem leads to ensure proper packaging, especially in the foot box and hubs of the car, where most of the braking components are placed. Quality checks were essential for manufactured, OEM, and after-market components.
Manufacturing in Baja SAE
As a Usability design lead, I oversaw the manufacturing of the system's parts and worked with the chief mechanic to follow the manufacturing schedule. During production season I spent over 30 hours per week creating tool-paths for CNC manufacturing as well as machining in the mill and lathe. All pieces were checked for tolerance to ensure fit.
During my first two years in the team, I was involved in frame manufacturing, composites and the complete assembly of the car. During building season I spent 25+ hours a week in the shop. I was dedicated to the team, which are know part of my family. The time spent at the shop was not in vain, I learned how to use the majority of the shop tools; the mill, lathe, angle grinder, a bit of welding, fiberglass, and plastics. I was challenged with problems from all aspects of the build process, design interferences, manufacturing mishaps, misplaced orders, etc. I often had to think out of the box to solve them in non-traditional ways that will still comply with the competition rules and ensure drivers safety. Baja helped me to develop my skills as a mechanical engineer and directly apply what I was learning in the classroom to a real-life project.
