Company/Client
Cooper Motorsports
Role
Aerodynamics Lead
Timeline
2019 - 2021
Skills
Surface Modeling Carbon Fiber Layups CFD Patterns & Molds
Tools
SolidWorks Siemens NX Ansys CNC
Problem Statement
During my time at Cooper Motorsports, I was tasked with designing and manufacturing the aerodynamic package of a Formula SAE racecar. This intricate task required detailed surface modelling, complex fluid dynamic simulations, and carbon fiber layups.
Approach
In order to accomplish this, I had to do the following:
Discover opportunities for improved downforce and heat transfer by learning fluid mechanics
Model surface geometries based on relevant academic literature and prior team work
Iteratively analyze and validate the aerodynamic package through simplified CFD simulations and hand calculations
Fabricate foam molds using a CNC for the nosecone and sidepods
Manufacture carbon fiber exterior in vacuum bag layups with varying composite orientations
