Monocoque R&D and Testing
Researched and developed a structural testing plan and hardpoint mounting strategies for Formula SAE competition compliance and potential monocoque integration for the 2028 UWFE vehicle.
Currently designing the required tooling, jigs, and fixtures for testing.
Full Research on Notion: Monocoque ‘28 R&D. Specific sections are linked below.
What?
FSAE rules (F.4.2) require structural equivalence testing on composite coupons replicating the monocoque to pass SES. This includes 5 required tests including 3-point bending, perimeter shear, lap joint, harness attachment, and steel comparison
Hardpoint installation methodology needed to be established for mounting metal suspension and chassis components to the carbon fiber monocoque
How?
Researched all 5 required FSAE SES tests, documenting specimen geometry, tooling requirements, force minimums, and rules references for each (More details can be found here: Tooling for Composites SES 2028
Coordinated with a professor at UW's Forming and Crash Lab to confirm on-campus testing capability, identifying available equipment including a 100kN+ universal tester
Researched hardpoint installation methods including co-cured inserts, potted inserts, Torlon inserts, rivet anchors, and bonded studs, comparing load capacity, and compatibility with carbon fiber (More details can be found here: Hardpoint Mounting Methods)
Documented a full hardpoint location process for a female mold based on Western Michigan's methodology including CMM hole locating, core boring, and epoxy injection (More details can be found here: Female Mold Hardpoint Location Method)
Universal Tester that can apply 100kN+ of force.
Recommended machine for lap joint test.
Results?
Produced a complete tooling requirements list covering all 5 SES tests with rules references. Confirmed necessary testing lab equipment could be provided by the school, but custom fixtures and jigs needed to be designed to fit FSAE testing rules
Currently designing the required tooling, jigs, and fixtures for all 5 SES tests based on the documented specifications and lab equipment constraints
Delivered a hardpoint installation guide and mounting method comparison to support potential monocoque implementation for the 2028 UWFE vehicle
