Kevin Chang
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04 of 11FSAE Team

Anteater Electric Racing

FSAE Electric Racecar Chassis

Chassis engineer on UCI's Formula SAE Electric Racing team. I led FEA-driven optimization of the 4130 chromoly steel chassis, validating the structure against FSAE's torsional rigidity and impact requirements while reducing weight by 11%.

Role
Chassis Engineer
Year
Apr 2023 to Oct 2024
Category
FSAE Team
Tools
SolidWorksFEA4130 ChromolyTIG / MIG
GalleryClick any image to expand
FSAE chassis CAD01 of 02
FSAE chassis detail02 of 02
01

Overview

Anteater Electric Racing is UCI's Formula SAE Electric team. As chassis engineer I owned weight reduction, structural validation, and the manufacturing strategy that turned the CAD model into a welded steel space frame.

02

What I owned

  • Reduced 4130 chromoly steel chassis weight by 11% (4.7 kg) through FEA-driven optimization in SolidWorks, while holding the required factors of safety and FSAE-compliant torsional rigidity.
  • Ran multi-load-case FEA: 120 kN front impact, 80 kN side impact, and torsional rigidity to benchmark against the previous chassis.
  • Researched and benchmarked 9 FIA-certified racing seats and 6-point harness configurations against FSAE safety regulations using a decision matrix, optimizing for driver ergonomics and structural integration.
  • Designed a weatherproof safety-control enclosure to house AIR control relays and safety switches, with a removable access panel and gasket sealing; tuned fit through iterative 3D-printed prototypes.
03

Takeaways

FSAE forced me to get comfortable defending design decisions with simulation and data, then living with the consequences once the welds were laid down. The chassis is the most concrete piece of engineering I have my name on.

Next project →

FSAE Welding Fixtures

Sub-Millimeter Tooling for Chassis Build