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 the hands-on assembly and integration of braking system components, including installing rotors and calipers, routing and bleeding brake lines, packaging ABS hardware within the cockpit, and fabricating a heel stop for the pedal box. 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 and analysis for the electric car, calculating shock absorber requirements from vehicle mass and load transfer data derived from cornering, braking, and bump scenarios. I assisted with the installation and setup of control arms, rod-end bushings, and suspension linkages based on weight and performance requirements. I also contributed to the carbon fiber layup process for the vehicle's body panels.

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