Interchangeable Sprockets and Adapter
Designed a topologically optimized sprocket adapter and set of sprockets for UWFE's driveline subsystem
What?
Our current custom limited slip differential design forces sprockets to be swapped with a complete disassembly due to a smaller bolt pattern
New sprockets and an adapter are required to change the final drive ratio easily without having to take apart the differential
How?
Designed an adapter incorporating bolt shear calculations, topology optimization, and Ansys structural simulations
Engineered a set of sprockets (36T, 38T, and 40T) with SolidWorks and Ansys to be compatible with the adapter
Verified sprockets and adapters with additional Ansys static structural simulations with worst-case loading
Results
Final drive ratios can be altered during testing sessions, providing data to determine which sprocket combination is best for acceleration, endurance, or autocross
Reduced baseline sprocket weight from 300-500g to below 200g
Achieved a FOS greater than 2 for both equivalent stress and fatigue life, similar to 2025 vehicle components
Reinforced SolidWorks modeling and Ansys simulation skills
Motor Guard
Designed and manufactured an FSAE rules legal scatter guard to enclose the EMRAX 228
Chain Guard
Designed and manufactured an FSAE rules legal scatter guard for the driveline subsystem
Trace It
Trace It is a hands on target practice toy, utilizing two motors and an infrared gun
Capturally
An EV3 robot that can capture videos and images using tracking and keyframes
Curtiss-Wright Co-op Projects and Designs
Mechanical designs and rapid prototyping at Curtiss-Wright
Final Drive Ratio Analysis
Performed analysis on UWFE 2026 vehicle to determine appropriate gear ratios
Differential Assembly and Spacers
Ensuring critical rotation and mounting of the custom limited slip differential
Harness Mounts and Jigs
I created four pairs of chassis harness mounts to ensure the driver has a legal harness for Formula SAE Electric events.
Chassis Front Enclosure Mount
Created a laser cut jig in order to accurately position the front enclosure mount within 2 millimeters laterally and longitudinally
Half Shaft Plungers
R&D Propulsion task for UWFE Driveline subteam
LED Dice
Fully custom made LED Dice PCB
TT Motor Dynamometer
I constructed a dynamometer out of TETRIX to measure the speed and torque characteristics of a TT motor