LV Battery & Enclosure
Re-designing a battery enclosure for the '26 LV system to replace the previous 46Ah cell with a smaller 15Ah one.
In Progress
CAD
DFM
Hand Calculations
What?
Previous 46Ah battery and enclosure were oversized after adding a DC/DC converter, making a smaller 15Ah LiPo viable
New enclosure needed to be FSAE rules-compliant, protect the battery from vibration, and integrate cleanly with adjacent components
Current 46Ah enclosure for reference only (not designed by me)
How?
Evaluated 20+ battery candidates using a design matrix, performing worst-case power draw calculations to validate minimum capacity
Currently designing a 3D printed enclosure in PC-FR filament, looking into mounting methods for serviceability
Analyzing and performing hand calculations to optimize inner foam padding thickness for mass
Results?
The 15Ah cell’s surface area is ~43% less than the 46Ah one. I'm targeting roughly the same mass reduction for the enclosure
Set to finish before FSAE Michigan competition on June 16
