Design & CAD

Design & CAD

Engineering & Fabrication

Custom Airfoil

Challenge

Challenge

  • Design a unique airfoil geometry optimized for aerodynamic performance
  • Model the airfoil in CAD with a 6-inch chord length for 3D printing
  • Conduct wind tunnel testing using pressure measurements along the surface
  • Evaluate lift and drag performance across multiple angles of attack to assess efficiency and stability
Approach

Approach

  • Used a pitot-static tube to measure airspeed in the wind tunnel via total and static pressure differences
  • Integrated pressure taps at the stagnation point and multiple locations on the upper and lower airfoil surfaces
  • Connected each tap through the hub to a pressure sensor for data acquisition
  • Applied a calibration equation to convert measured voltages into pressure values for analysis
Solution

Solution

  • Showed theory-consistent behavior for the coefficient of lift vs. angle of attack
  • Displayed an approximately linear relationship from 0° to 10°, with a peak lift coefficient of 0.46
  • Demonstrated a smooth increase in lift without premature stall behavior
  • Confirmed a successful airfoil design with stable, reliable, and predictable lift performance within the tested range

Volt-Veil

Volt-Veil 1
Volt-Veil 2
Volt-Veil 3
Volt-Veil 4
Volt-Veil 5
Volt-Veil 6

Challenge

  • Identify and evaluate market opportunities through brainstorming, weekly observations, and targeted questions
  • Apply design and feasibility criteria to narrow potential product ideas
  • Select Volt-Veil, a zero light-bleed, automatic curtain system, for its large market potential
  • Conduct market analysis through customer surveys

Approach

  • Planned and managed the project using structured tools such as a Gantt Chart, DSM Chart, and resource allocation table
  • Identified customer needs through surveys and analysis, translating them into measurable target specifications and a Quality Function Deployment (QFD) matrix
  • Developed and evaluated design concepts using concept generation, concept screening/scoring, and Failure Modes & Effects Analysis (FMEA)

Solution

  • Utilized CAD modeling to design, prototype, and refine the curtain's mechanical and housing components
  • Integrated a stepper motor, microcontroller, and programmable timer to enable automatic opening and closing
  • Validated performance through assembly analysis, cost evaluation, and functional testing

Parking Brake System

Challenge

Challenge

  • Must hold the fully loaded car on dry pavement against a 10% weight force without wheel chocks
  • Operates independently from the main braking system and is excluded from main brake tests
  • Must lock in place, be set from the seated, belted position in one motion
  • No tire or wheel-contact designs allowed—must fit within tight space constraints
Approach

Approach

  • Designed a dedicated rear caliper system mounted independently from the main hydraulic brakes
  • Developed a simple lever mechanism that locks securely in place
  • Ensured the system is operable from the seated, belted driving position in one motion
  • Iterated on packaging to fit within the vehicle's tight space constraints
Solution

Solution

  • Developed a parking brake system that fits within the vehicle's tight space constraints
  • Utilized a dedicated rear caliper mounted on the left rear wheel fully separate from main braking
  • Featured a simple lever mechanism that locks securely in place and is easy to operate
  • Successfully passed the 10% pull test

Aeroshell Manufacturing

Challenge

Challenge

  • The solar car aeroshell exhibited surface roughness, gaps, and misalignment between top and bottom halves
  • The shell was structurally weak and flexible making it difficult to remove or reassemble
  • These issues led to aerodynamic inefficiency during coast-down testing
Approach

Approach

  • Undertook a remanufacturing process to rebuild the aeroshell using refined fiberglass layups and carbon fiber reinforcement
  • Focused on closing gaps between shell sections and ensuring smooth exterior surfaces
  • Prioritized durability and serviceability
Solution

Solution

  • Successfully eliminated gaps and reduced surface imperfections
  • The carbon-fiber-reinforced shell provided increased stiffness
  • Coast-down testing confirmed a significant reduction in aerodynamic drag

Analog/Digital Automotive Designs

Automotive Design 1
Automotive Design 2
Automotive Design 3
Automotive Design 4
Automotive Design 5
Automotive Design 6
Automotive Design 7
Automotive Design 8
Automotive Design 9
Automotive Design 10
Automotive Design 11
Automotive Design 12
Automotive Design 13
Automotive Design 14
Automotive Design 15
Automotive Design 16
Automotive Design 17
Automotive Design 18
Automotive Design 19
Automotive Design 20

Brutalist Side Table

Brutalist Side Table 1
Brutalist Side Table 2
Brutalist Side Table 3
Brutalist Side Table 4
Brutalist Side Table 5
Brutalist Side Table 6
Brutalist Side Table 7
Brutalist Side Table 8

Challenge

  • Create a mid-century modern/brutalist side table with solid woods and concrete
  • Must feature 3 drawers—with the top drawer concealed to preserve brutalist look
  • All edges and seams must be precise and symmetrical

Approach

  • Created a prototype in CAD to establish scaling and facade
  • Used a miter saw, table saw, circular saw, and planar to cut solid white oak and pine
  • Cut all of the top-drawer edges to 45 degrees to conceal it from all angles
  • Created hollow concrete base molds with 90-degree and 45-degree interior corners

Solution

  • All drawers have soft close rails and line up flush between each other with minimal gap
  • The second iteration concrete mold displayed resistance to cracks
  • Implementation of veneer oak on the back face saved weight to increase mobility