SolEater

CHALLENGE

Design a Solar Car to compete in an annual Solar Car Grand Prix in Bowling Green, Kentucky. Build the vehicle to pass scrutineering and compete in the endurance race.

Aerobody Subteam

Design, manufacture, and implement an aerodynamic shell component onto the car. My main roles involved composite manufacturing and CAD integration.

TEAM

A team of 9 UCI Students
working on our Aerobody.

TIMELINE

(Sep 2024 – Present)

Techniques

CNC
Composites
CAD

Manufacturing Steps

Construct Shell Components
Shell Surface Work/Repair
Combine Shell Components
Integrate onto Chassis/Rest of Car

Hover to learn our process

Topshell Divinycell Layer. Laid in between two single ply fiberglass.

Bare aluminum top shell mold. Layup was done on top of the surface.

Topshell layup vacuum process.

Topshell out of mold, with foam rigidification adhered.

Bare aluminum side shell mold.

CNCing foam for male plug on sideshell layup.

Male plug for side shell layup. Duratec coat spray painted on to protect against bondo.

Side shell layup #1

First side shell result.

Side shell layup #2

Trimming excess fiberglass on side shell.

Full cut top shell laid ontop of side shell for the first time.

Two side shells being adhered together

Canopy layup

Fully CNC'd foam mold for Canopy

Sideshell fully put together and bottom lips cut.

Sideshell bulkheads adhered for reinforcement.

Canopy cut and ready for latching.