P09221: Innovative Composite Parts for a Formula SAE Racecar Chassis Concepts: Slides 2-3 Pedal Box Concepts: Slides 4-5 Undertray Concepts: Slides 6-8

Chassis Roll Hoop Attachment: Bolted Bolted and Bonded Co-cured and bolted Cut out/contour flange Solid planar flange & move fuel cell Chassis Shape: Curved panels Flat, planar facet Facets with slight curvature/twist

Chassis Chassis Manufacturing Wood/MDF/Fiber Glass/Tooling Board Plug Metal Template Plug (Photo: Harbor Patterns F-22 Canopy) Graphite Pre-Preg Mold (Photo: Harbor Patterns Bell Helicopter Skin Mold) Gel-Coat/Fiberglass Mold

Pedal Box Stiffening Scheme: Flat plate w/ core under pedal box Rectangular bonded inserts Ribs bonded in channels Manufacturing Concepts: Plastic/metal plate with milled channels – Simple mold making process Solid carbon with channels milled in it – No mold required, wastes a lot of carbon and tooling Pultrusion – Expensive, Increased axial properties, ease of mass production Vacuum Bagging – Cheap, simple, allows any fiber orientation Infusion – Cheap, complicated, allows any fiber orientation Compression Molding – Very simple, poor fiber to resin ratio, allows any fiber orientation

Pedal Box Pedal Channel Concepts: Smooth, Large Radii – Ease of Part Manufacturing, lower peak normal/in-plane stress Sharp Corners/Small Radii – Ease of mold manufacturing (no ball-end mill or surfacing required), lower out of plane/interlaminar stresses from radius bending Ribs bonded in channels – less weight added in stiffeners Stiffening Rectangles Bonded in Channels – Greater bond surface area, greater stiffness gains

Undertray Tunnel Geometry: Large Radii – Ease of Manufacturing Sharp Corners – Better flow properties Extend Past Rear Wheels – Better flow properties Shorter than Rear Wheel Centerline – Legal, Lighter, Easier to manufacture Smooth, Elongated Tunnel Curves – Better flow properties Flat Plate Facets for Tunnels – Ease of Mold Making

Undertray Stiffening: Stiffeners in flow Add no stiffeners Stiffen above tray

Undertray Jacking Point Concepts: Carbon: Integrated into tray, jack up car w/ tray Aluminum: Bonded onto tray, jack up car w/ tray Steel: Cut out undertray, weld steel to chassis, do not jack up car w/ tray Jacking Point Regulations: Must be painted orange Higher than 3” off ground but below 6.9” Visible from 3 feet away Bottom half of tube must be exposed Material: steel or aluminum