1. 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

2. 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

3. 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

4. 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

5. 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

6. 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

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

8. 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