The first image is the failed prototype, it did not properly align with the frame and needed to be scrapped which was bad for deadlines. This was due to trying to create one jig for the rear and front thus creating a more complicated jig to print. The second image is the final jig that was used for welding. It featured 4 jigs with various lengths. I learned that overengineering something is impractical and instead kept it simple for manufacturing.
Damper Jig Design and Fabrication - CT-16 Suspension
Steven Andrade
Project Timeline
Dec 2024 - Jan-2025
OVERVIEW
Designed and fabricated a damper welding jig for the CT-16 internal combustion UConn Formula SAE car. Accuracy was achieved by converting the suspension geometry (lines, circles, and alignment references) into a SolidWorks model, allowing the jig to position the damper tabs exactly as defined by the subsystem lead. Those tabs were welded on while bolted onto the jig and used to mount the damper component of the the suspension subsystem.
HighlightS
- Modeled damper jig components in SolidWorks, incorporating 3D‑printed alignment features and machined steel supports.
- Used suspension geometry provided by the subsystem lead, represented as reference lines in SolidWorks to design the jig and ensure proper damper alignment before welding.
- Iterated through two design versions: the first was over‑constrained and inaccurate due to 3D printing complications
- The second design was simpler and only targeted 1 weld spot at a time
- Fabricated jig using FDM 3D printing and bandsaw
- Supported suspension integration by ensuring accurate damper placement on the CT‑16 IC car frame.
- Also modeled pull rods and tie rods for the suspension system, and machined A‑arm tabs with precise dimensional control using a lathe.
SKILLS
CAD ModelingSolidworks3D PrintingMachining (Lathe, Mill, Bandsaw)Design for Manufacturability
ADDITIONAL CONTENTS
Steven Andrade
A student pursuing a career in Engineering Design
I am a passionate Mechanical Engineering student at UCONN who previously interned at ASML. I am actively learning skills such as CFD modeling to use in the jobsite. I am involved in working on both the powertrain and suspension systems at Formula SAE. I am committed to learn and work cooperatively in a team environment.
I am a passionate Mechanical Engineering student at UCONN who previously interned at ASML. I am actively learning skills such as CFD modeling to use in the jobsite. I am involved in working on both the powertrain and suspension systems at Formula SAE. I am committed to learn and work cooperatively in a team environment.