Aerodynamics · Manufacturing · Leadership
Formula SAE
Aerodynamic design, structural development, and composite manufacturing for Mississippi State’s Formula SAE car.
Overview
I led development of a vehicle aeropackage combining multi-element wings, cooling ducts, an undertray, and mounting structures. The work connected analysis with fabrication, deadlines, and vehicle testing.
My contribution
I directed 10 core members, owned a $5,400 section budget, and trained teammates in CAD and CFD. I coordinated design, manufacturing, and trackside adjustments, then documented lessons for the next section lead.
Engineering approach
I established the team’s first CFD design workflow, automated XFOIL sweeps with Python, and developed a MATLAB/OptimumLap workflow for lift–drag trades. Structural development combined FEA, hand calculations, aluminum wing skeletons, swan-neck mounts, and wire bracing. Split-shell carbon layups and CNC-machined MDF molds translated the design into hardware.
Results & current status
The 2026 front wing weighed 10% less than the directly weighed 2024 wing. Revised shells and mounts eliminated the flex and rib tear-out observed during testing. Every driver improved practice skidpad times by 2–3 seconds after aeropackage installation; these were practice observations, not controlled isolation of aerodynamic effects. An engine failure prevented the endurance event.