Formula SAE Electric — Ergonomics & Vehicle Dynamics

As an active member of USC's competitive Formula SAE Electric program, I contribute to two concurrent sub-teams — Ergonomics and Vehicle Dynamics — working to design, manufacture, and validate systems on the team's electric open-wheel race car. The program competes under SAE International rules, requiring strict compliance in safety, packaging, and performance across every subsystem.

Pedal Box Design & Braking System

On the Ergonomics Team, I was responsible for the design and analysis of the driver interface — specifically the pedal box assembly including the brake pedal, brake bias bar, master cylinders, and mounting plate. The USC-branded aluminum pedal plate was modeled in Siemens NX, balancing lightweighting (patterned cutouts and slots) with stiffness requirements under driver braking loads.

Beyond CAD, I participated in hands-on manufacturing of braking system components: machining rotors and calipers, routing and bleeding brake lines, and integrating ABS hardware into the cockpit packaging. The pedal box is adjustable for driver fit and mounts within the tight ergonomic envelope defined by FSAE rules.

NX CAD — pedal box plate · Installed brake assembly · Balance bar hardware · Ergonomics fit check

Suspension Design & The Car

On the Vehicle Dynamics Team, I performed suspension system design for the electric car, calculating shock absorber requirements from vehicle mass and load transfer data derived from cornering, braking, and bump scenarios. I designed and manufactured control arms, rod-end bushings, and suspension linkages to meet target roll center and motion ratio specifications.

The finished vehicle — car #289 — is a full open-wheel electric race car built to SAE Formula specification, featuring custom aerodynamic bodywork, a purpose-built electric powertrain, and the full suite of mechanical systems the team has developed in-house.

Car #289 in the team shop · Outdoor roll-out on the USC campus