Northwestern Formula Racing

Problem-Solving Under Ambiguous Requirements: Collaborated with cross-functional engineers to derive requirements for first-generation designs, prioritizing vehicle performance, safety, budget, manufacturability, and thorough documentation.

3D CAD Modeling: Designed the 1000+ part battery pack assembly in SolidWorks to be manufactured using 3D printing, welding, and sheet metal bending and cutting. Validated designs with robust FEA simulations to withstand impacts >40gs.

Integration and Test: Integrated complex electromechanical assembly with PCBs, wire harnesses, battery cells, plastics, adhesives, and conductive metals to be electrically insulated for 600V and non-flammable per UL94-V0 specification.

Problem: excessive voltage drops led to inconsistent engine turnover and unexpected car shutdowns. Solution: implemented functionality to automatically cut power to certain devices based on battery voltage. Successful design led to the first competition in recent years where electrical issues didn’t compromise performance.

Problem: due to the iterative nature of the inherited design and a lack of documentation, the PDM’s layout was confusing, and its functionality was minimally understood. Solution: fully redesigned the PCB with a more comprehensible layout and thoroughly documented it for future team members’ understanding. Built consensus on design choices with teammates and subteam lead by organizing in-depth design review meetings. 

Through this project, I gained experience with PCB design, Arduino CAN integration, and power optimization.