For my undergraduate senior design project, I helped build a car for the SAE Baja competition. On the drivetrain team, I was responsible for redesigning the rear frame to properly mount drivetrain components, engineering the suspension system to handle competition jumps, machining suspension and drivetrain mounting hardware, and welding the rear frame assembly.

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Frame Design and Fabrication: Using SolidWorks, I designed a structurally stable rear frame that accommodated our differential, gearbox, and engine mounts. I prepared technical drawings for the tube bending shop and, when additional support members were needed during assembly, I personally notched the tubes using precise angle measurements on our mill. Photos of these unique mill setups are shown below.

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Suspension Analysis: After discovering the previous year's team hadn't performed engineering analysis on their shock selection, I developed a comprehensive evaluation system. Drawing from my engineering vibrations and linear algebra coursework, I created a two-degree-of-freedom model of the car. Using modal vibration analysis, I calculated the maximum jump height the car could safely handle based on the shocks' spring constants and damping coefficients. For a detailed explanation of this model, please see my presentation: