Formula SAE Suspension

Project Overview

As suspension lead on the university Formula SAE team, I redesigned the front double wishbone system from scratch. The project required balancing dynamic performance targets (camber gain, roll centre migration) with strict weight limits and the team's machining capabilities. All components were validated in ANSYS before manufacture.

Key Highlights

• 30% weight reduction over the previous season's design
• ANSYS FEA validation of uprights, a-arms, and pull rods
• CNC-machined uprights from 6061-T6 aluminium billet
• Achieved target camber gain curve within 2% tolerance
• Full GD&T drawing package produced for machine shop