The Formula SAE (FSAE) chassis design focuses on developing a lightweight, safe, and high-performance tubular frame for a race car. This frame forms the structural backbone of the vehicle, supporting all critical subsystems, including suspension, powertrain, bodyworks, aero package, and driver ergonomics.

I led the chassis department at SPCE Racing for two years, overseeing the design and fabrication of the chassis for two national competitions: Formula Bharat 2019 and 2020. We utilized CATIA V5 for 3D CAD modeling and ANSYS for digital analysis (FEA), including crash simulation, torsional stiffness analysis, and structural assessment of critical mounts.

To enhance our fabrication process, I engineered a laser-cut jigsaw steel fixture for precise assembly of the AISI 1018 tubular roll cage. Additionally, I developed a torsional stiffness test rig to validate the simulated torsional stiffness of the FSAE chassis. For the 2020 season, I also designed the team’s first aluminum bulkhead for mounting critical powertrain and suspension assemblies. My role involved ensuring cross-functional team coordination for accurate mounting and assembly of over 120 interfaced components.

We achieved 4th place in the Design Event and an overall rank of 6th place nationwide at Formula Bharat 2020. Click HERE to see the detailed report.

Welding Fixture CAD model

Laser-cut Jigsaw Welding Fixture

FEA of Welded Suspension Mount

FEA of Bolted Suspension Mount

Front Suspension Geometry Mounting

Powder Coated Chassis

Our Car at Formula Bharat 2020

Our Car at Formula Bharat 2019

Design Event Presentation at Formula Bharat 2020

At the Workshop