FSAE Space Frame Chassis

As Lead Chassis Engineer for SDSU's Aztec Electric Racing team, I'm responsible for the structural design and fabrication of our FSAE competition chassis. The chassis is a TIG-welded steel space frame optimized for torsional rigidity and minimum weight while remaining fully FSAE rules compliant.

Key contributions include redesigning the assembly jig with 25% tighter manufacturing accuracy using 3D-printed carbon fiber nylon filament (PET-CF), creating new load-path supporting structure for suspension and rear wing swan neck mounting, and pivoting to outsourced tube notching — saving 8 weeks of fabrication time for additional system testing.

I lead a team of 11 engineers across subteams covering chassis documentation, assembly process optimization, ANSYS simulation, and integration with all other technical teams. We also incorporated GD&T (ASME Y14.41, Y14.5) across manufacturing drawings and implemented SolidWorks PDM for design version control and configuration management.