Formula Student Electric: Squadra Corse Polito

Formula Student Electric: Squadra Corse Polito

Oct 2017 - Aug 2018 · Turin, Italy

In the second year of my Masters in Turin, I was honored to be part of the Squadra Corse Polito Team for the 2017 - 2018 Formula Student Electric season.

I became part of the Unsprung Masses division during the design phase of the new SC18 Integrale car. My task was to design the wheel uprights and the brake rotors. However, later on, while finishing the design and starting the prototyping and testing phase, I became the division leader.

It was really challenging experience, but I really enjoyed being part of the team and building an electric race car from scratch.

We achieved 3rd place in the Formula SAE Italy 2018 competition.

Part of the hard skills I reinforced during this experience can be summarized:

  • 3D modeling of lightweight mechanical parts and assemblies with CATIA V5 and structural optimization with Altair Optistruct
  • Carrying analytic preliminary design of vehicle systems (brakes)
  • Design exploration of components using ANSYS DOE studies (brake rotors)
  • Coupled thermal and mechanical stress analyses (ANSYS Workbench) and correlation with track tests data (Matlab)
  • Realization of manufacturing drawings and specifications for various suspension, steering and brake system components, according to standard GD&T specifications for CNC and manual machinery (lathe, milling machine, laser cutting, wire EDM, grinding machine, etc.).
  • Using additive manufacturing for producing plastic prototypes (FDM) and functional aluminum parts such as optimized hydraulic fittings and structural brackets (SLM)

Skills: Matlab · Experimental Data Analysis · Finite Element Analysis (FEA) · Prototyping · English · Computer-Aided Design (CAD) · 3D Printing · SolidWorks · Manufacturing · ANSYS · CATIA · Microsoft Excel