Baja SAE Design Competition

1
Baja SAE Design Competition
Baja SAE is an international design competition
sponsored by the Society of Automotive Engineers.

• Student designed and fabricated
• Simulate real-world engineering design project
• Three North American competitions per year

2
Team Organization Structure
Team setup ensures efficiency in design and
communication

• Top down structure aids in easy team member
  communication
• Leadership team
• Three sub-teams and respective leaders

3
Chassis Design Overview
Chassis primary objective is to make a sleek,
lightweight frame while conforming to all the
safety standards set forth by the SAE.
Final frame design Modification -- fabricating
testing and evaluation
4
Safety
Conforming to safety standards is the most
important objective when designing the Baja
vehicle.

• Safety harness on car
• Safety equipment
• required to be worn at
• all times
• Fire extinguisher on
• board

5
Final Design
The final design was developed from the initial
frame concepts.

• Maximize design efficiency
• Weight Reduction
• Maximize frame strength

6
Prepping for Fabrication
Creating a frame jig is the key to manufacturing
an accurate chassis.

• Precisely machined
• Bolted to welding table
• Allows floor members to be accurately placed
  according to the design

7
Fabricating
8
Bending Slide
How to bend Feeding tube in bender, clamp, bend
starts x-distance from die depending on die, bend
to angle springback Negatives of bender
inaccuracy in getting angle (overshooting to
compensate for springback) ,
Picture of Bender
9
New Seat and Body Panels
Making box for mold two-part urethane foam
shaping down to size overlaying with fiberglass
Picture of box?
Carbon fiber body panels
10
Flotation
One key component in the East competition
endurance race is water maneuverability.

• Currently designing for Minicel M200 buoyancy
  foam.
• Determining ways to minimize weight while
  retaining strength.