September 2017 — May 2018
George Washington University

logo design by Ali Ahmed

 

 

 

How do we create an off road competition vehicle lighter, while retaining safety of the driver?

Carbon Fiber

 
finished seat.jpeg

Black Glass

a lightweight carbon fiber + fiberglass racing seat unibody seat, encapsulating all mounting into carbon fiber

 

MATERIAL

SIZE

Carbon fiber, fiberglass, aluminum, steel, epoxy

h25 in . w24 in . l23 in


CLIENT

COMPLETION

GWU SAE Baja

April 2018

RECOGNITION

ROLE

Core77, @student.design, SAE, Local Motors, Finish Line

Industrial + Seat Design Lead
(Led 3 students)


SKILLS

Fusion 360speed form NURBS, Class B surfacing, CAM
CNC 5 axisThermwood router, high density foam
Carbon Fiber: manual manufacturing with professional boat workers

 

Process

  1. Surface + solid model chair - Autodesk Fusion 360,

  2. Optimize weight and shape w Generative Design - Autodesk Within

  3. CAM seat negative

  4. CNC seat negative on styrofoam block (5-axis machine, sponsored by Local Motors)

  5. Lay carbon fiber on mold

  6. Encapsulate chair mounts

  7. Mount chair to chassis

CAD

The process works such that I first design a CNC milled mold, from which we lay fiberglass onto. Atop the fiberglass reinforcement, lightweight carbon fiber will be laid to craft the final seat.

 

A distinct care for achieving ergonomic continuity

manufacturing, 5-axis cnc

The mill was a Thermwood CNC machine, supplied by sponsor,  Local Motors

The mill was a Thermwood CNC machine, supplied by sponsor, Local Motors

 

manufacturing / carbon fiber

 
19 seat drying.jpg

manufacturing time-lapse

 

    manufacturing, mount encapsulation

 
Artboard 6.png