ali ahmed | Studio
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Black Glass / 2018

 

SAE Baja is an international competition where a team of students collaborate in creating an off-road vehicle from scratch.

 

Black Glass is an example of seamless design for an extreme environment - carbon fiber for a off-road heavy duty Baja vehicle.

September 2017 - may 2018

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

George Washington University SAE Baja

April 2018

recognition

 

ROLE

Core77, @student.design, Society of Automotive Engineers, 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

Design / CAD + Iterations

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

 
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manufacturing time-lapse

 

    manufacturing / mount encapsulation

 
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