Aerodynamics Team | Formula SAE
Vehicle Aerodynamics and Sensor Integration Project
This project involved contributing to the aerodynamic development of a Formula SAE vehicle through component design, fabrication, and integration in support of vehicle testing and performance validation. As a member of the aerodynamics subteam, I worked at the intersection of CAD design, manufacturing, and hands-on vehicle integration to support airflow management, sensor placement, and rapid iteration during the development cycle.
My primary responsibilities included designing and fabricating aerodynamic support components and sensor mounting hardware. Using Siemens NX, I developed CAD models for mounts and brackets intended for airflow measurement, sensor integration, and experimental setups. Designs emphasized manufacturability, structural rigidity, and compatibility with existing vehicle geometry, enabling quick installation and removal during testing sessions.
Manufacturing played a central role in this work. I produced precision aluminum components using manual machining processes including lathe and mill operations, as well as CNC machining where appropriate. These parts were fabricated to tight tolerances using GD&T principles to ensure repeatability and proper fit across multiple assemblies. For rapid iteration and early-stage validation, I also designed and 3D-printed components in PLA, allowing the team to quickly test concepts before committing to machined hardware.
The project required close collaboration with other subteams to ensure aerodynamic components did not interfere with suspension, electronics, or vehicle packaging constraints. This cross-functional coordination helped align aerodynamic experimentation with overall vehicle performance goals and testing schedules.
Through this experience, I gained practical exposure to real-world aerodynamic development workflows, including iterative design, rapid prototyping, and integration under time and resource constraints. The project strengthened my skills in CAD-driven design, precision manufacturing, and engineering communication, while contributing directly to the team’s ability to test, validate, and refine aerodynamic concepts on a competitive Formula SAE vehicle.
