Kevlar Front Enclosure Lid
Led the layup session of a Kevlar composite lid to create a waterproof FSAE legal electrical enclosure.
What?
The front electrical enclosure houses the Vehicle Control Unit (VCU) and requires a waterproof lid to meet IP65 sealing requirements
Previous year's lid was aluminum, adding unnecessary mass
Needed to be lightweight, structurally sound, and most importantly pass the FSAE rain test
How?
Kevlar was selected over carbon fiber due to its non-conductive properties, making it safer for an electrical enclosure, and preferred over fiberglass as it doesn't produce harmful shards during cutting
Using a pre-designed 3D printed mold, a PVA mold release agent was applied before laying up Kevlar plies in a [0°/45°/-45°/90°] orientation
The part was placed under a vacuum bag overnight, then trimmed to fit and an O-ring was added for IP65 waterproof sealing
Results?
Passed the rain test safety inspection at FSAE competition, proving the lid successfully achieved IP65 requirements
Reduced lid mass by 85% over last years aluminum design
