Generative Design and 3D Printing for Novel Solar Car Roll Cage Manufacturing
Abstract/Contents
- Abstract
- Working with our sponsor, the Stanford Solar Car Project (SSCP), our team was responsible for the design and manufacturing of the occupant cell for SSCP’s current, in-production solar car. We took a particular focus on its roll cage, the physical structure that protects the driver in the event of the car rolling over, to ensure that it not only benefits vehicle performance but also keeps the driver safe. This paper describes our approach to achieving this through a novel solution involving generative design and selective laser melted (SLM) aluminum alloy. Evaluation through Finite Element Analysis (FEA) found that our roll cage design maintains a higher factor of safety than previous Stanford Solar Car Project roll cages while achieving a significantly lower mass. Further evaluation measures included destructive testing on its means of integration with the chassis as well as material validation to ensure that our desired mechanical properties were achieved. Despite the application of new design and manufacturing techniques, we built confidence in our design by mitigating risk through FMEA and receiving the approval and technical support from additive manufacturing industry specialists. As a result, we anticipate integrating this roll cage with SSCP’s vehicle and unveiling it to the international solar car racing community at the next race.
Description
| Type of resource | text |
|---|---|
| Date created | 2021 |
Creators/Contributors
| Author | Chiu, Daniel |
|---|---|
| Author | Haynesworth, Cameron |
| Author | Roise, Erik |
| Author | Sastry, Suhas |
| Advisor | Gerdes, Chris |
| Advisor | Su, Lester |
| Advisor | Wang, Celine |
| Sponsor | Stanford Solar Car Project |
Subjects
| Subject | generative design |
|---|---|
| Subject | 3D printing |
| Subject | solar car |
| Subject | roll cage |
| Subject | Stanford Solar Car Project |
| Genre | Student project report |
Bibliographic information
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- Use and reproduction
- User agrees that, where applicable, content will not be used to identify or to otherwise infringe the privacy or confidentiality rights of individuals. Content distributed via the Stanford Digital Repository may be subject to additional license and use restrictions applied by the depositor.
- License
- This work is licensed under a Creative Commons Attribution Non Commercial 3.0 Unported license (CC BY-NC).
Preferred citation
- Preferred Citation
- Chiu, Daniel; Haynesworth, Cameron; Roise, Erik; Sastry, Suhas. (2021). Generative Design and 3D Printing for Novel Solar Car Roll Cage Manufacturing. Stanford Digital Repository. Available at: https://purl.stanford.edu/xh318hs8716
Collection
ME170 Mechanical Engineering Design
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- engreference@stanford.edu
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