Project Summary

I worked as part of a five-person team to design and build a compact potential-energy–powered (PEP) racer, focusing on achieving maximum performance within strict size, mass, and component constraints. The final competition required the teams to choose obstacles to try to overcome while traveling the furthest distance along a two-foot-wide track. Using SolidWorks, I contributed to the development and iteration of multiple drivetrain concepts, evaluating tradeoffs in efficiency, packaging, and reliability to converge on an effective final configuration that was a top performer in the class final competition.

I also supported rapid prototyping and fabrication through 3D printing, which allowed us to quickly test design changes, integrate standardized components, and refine the vehicle’s layout. Through iterative design and hands-on validation, the team optimized overall system performance and competition readiness. 

Rapid Prototyping

Multiple drivetrain and chassis prototypes were constructed using 3D printing to test various propulsion methods. The methods tested were:

• Linear spring power + carbon fiber/PLA chassis

• Fan/supercapacitor + springs + PLA chassis

• Fan/supercapacitor + lightweight carbon fiber chassis 

It was determined that the fan/supercapacitor and lightweight carbon fiber chassis provided the greatest power-to-weight ratio (6 times greater than linear springs and necessary chassis). The final powertrain/chassis design weighed 45% less than previous designs. Weighing only 146 grams, our final car was the 2nd lightest out of 28 teams.