Headrest Layup
Fabricated a lightweight carbon fiber headrest plate to provide proper driver head support.
What?
FSAE rules require a head restraint to limit rearward head motion and withstand a minimum force of 900N, ensuring driver safety during competition
Previous year's headrest plate was made out of 4130 steel, which made it unnecessarily heavy
How?
Carbon fiber was chosen for its high stiffness-to-weight ratio, making it ideal for a structural component that needs to withstand 900N of force while minimizing mass
Laid up 3 plies of 3K carbon fiber on each side of a HM80 1/4 inch foam core, then placed under vacuum bag to apply uniform pressure for a better surface finish
Results?
Reduced headrest plate mass by 78% over the previous steel design and passed technical inspection at FSAE competition
