Duke University Motorsports is a student group that designs and builds open wheel, single seat race cars to compete in the Formula SAE competition sponsored by the Society of Automotive Engineers. The team consists of Duke students from both Pratt and Trinity, in all classes. The purpose of the team is to provide students with a way to gain practical design and manufacturing experience in a fun and challenging setting.

Saturday, December 17, 2011

New hand clutch

More an exercise in surface machining than anything else, but we have to make a new one anyways.  Save a little bit of weight too - 100g vs 140g for the old one.  Not a whole lot, but every bit counts, especially when the weight savings is essentially free.

Some pictures of the machining process and the result of some of the 3D toolpaths after the jump.

Saturday, December 10, 2011


Things are moving along fairly well going into exam week.  We're almost done making our second diffuser (in order to reduce weight), which will be done with vacuum bagged foam panels attached together after they have carbon fiber laid onto them.

A pictorial update on progress:

Main diffuser piece in the vacuum bag

Sunday, December 4, 2011

The art of Upright making

Hey everyone,
I will explain the whole process we use to make uprights. Once you have your finalized Solidworks model for your upright you need to buy the stock needed for the operation.
Front Upright Solidworks Model

Rear Upright Solidworks Model

Saturday, December 3, 2011

Making wing end plates in the Universal Laser Cutter

We are starting to build the wings for the car which means we need to make the end plates for both wings (things that go on the sides of the wings). To make those we decided to make the molds out of foam core. You can first model them on Solidworks as you can see in the figures below:
Front Wing
Rear Wing End Plate