Title:

UNH Formula Student Controls

This project presents the design, analysis, and manufacturing of the controls system for UNH’s Formula Society of Automotive Engineers (FSAE) car. The specific components our team focused on were the pedal box, steering, and suspension assemblies. The goal was to develop a compact, ergonomic system that fits within the space constraints of our frame while meeting all FSAE rule requirements. Our design process involved using CAD, finite element analysis, and 3D printed prototyping. Through this, we were able to validate structural integrity and fitment before manufacturing our parts. During the manufacturing phase, several different processes were used such as waterjet cutting, 3-axis and 5-axis CNC milling, and lathe operations to name a few. Results include improved pedal adjustability, steering positioning and feel, and suspension functionality. Overall, this project successfully establishes a strong, competition ready controls system for UNH’s FSAE car.

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