This project explores the design and development of a Formula Society of Automotive Engineers (FSAE) chassis, focusing on the engineering design process and the challenges associated with meeting FSAE regulations. The project emphasizes a systematic, iterative approach to chassis design, balancing the critical factors of strength, weight, and structural integrity to ensure optimal performance and safety during operation. A key objective was to achieve a high strength-to-weight ratio while maintaining durability under the demanding conditions of competitive motorsport.

The design process began with a thorough review of the 2024 FSAE rules and regulations, which set specific requirements for dimensions, material selection, and safety features. These constraints guided the development of initial design concepts, which were progressively refined based on feedback from the capstone director and analytical testing results. The iterative approach allowed for continuous improvement, incorporating lessons learned from previous designs and insights from user feedback to fine-tune the chassis.

Material selection played a critical role in the design, with careful consideration given to the strength, weight, and manufacturing feasibility of various materials. Structural integrity was tested through simulation and physical validation to ensure the chassis would withstand the forces experienced during racing conditions. Additionally, different fabrication methods were explored to optimize cost-effectiveness while maintaining quality and performance standards.

This document provides a comprehensive overview of the design evolution, detailing the key factors that shaped the final chassis, from regulatory constraints and material choices to design testing and refinement. The result is a highly optimized FSAE chassis that meets the performance, safety, and manufacturing requirements of the competition.