NITK Racing Electric, the Formula Student team of NITK, underwent a remarkable transformation during the pandemic, shifting from the combustion category to the electric category. As the Technical Lead of this dynamic team, I've spearheaded design for simplicity and manufacturability and led a group of dedicated individuals. Together, we've embraced the challenges of the electric era, pushing boundaries and paving the way for a sustainable and thrilling future in the world of Formula Student racing
Leading a multi-disciplinary team in the mechanical design, manufacturing and testing of an electric race car
Established team goals and requirements based on vehicle-level modeling, competition points analysis, and reconciliation of historical failures
Provided leads with support for structural analysis, design reliability, and design for manufacturability
Led the creation of comprehensive documentation, encompassing vehicle design loads, milestone requirements, design review presentations, and Gantt charts, mirroring the dynamic responsibilities of running a startup by seamlessly blending technical and managerial tasks
Fostered a collaborative environment, encouraging knowledge-sharing and cross-functional expertise among team members
Secured a 5 Lakh sponsorship for the team through impactful engagement at an alumni meeting, showcasing strong negotiation and communication skills
Pioneered a lightweight design philosophy, by utilizing the technology of topology optimization in the design of the pedal box, saving the mass by 32%
Spearheading the vehicle dynamics simulation and overall vehicle modeling on MATLAB
Supervising the manufacturing of various structural and non-structural components of the car
Modelled and optimized the aerodynamic parts to achieve Cd less than 1.6 and a downforce of 500N at 15m/s
Manufactured the aerodynamic package and bodywork entirely in-house, resulting in 32 percent cost savings
I am thrilled to share the achievements of our team at Formula Bharat '23
Best Powertrain Design Award
2nd place in Business Plan and Presentation
Best Battery Design Finalists
Back in September 2022, I stepped into the role of an Aerodynamics and Composites Engineer. Armed with an angle grinder, I dived right in, cutting and shaping steel rods for the chassis. The team was in full swing, piecing together the chassis, and I was in the midst of it all – cutting, grinding, and welding using jigs and fixtures. It was hands-on learning from the start. But then came a pivotal moment – I was asked to redesign the car's nose cone, focusing on its aerodynamics. And so began the journey. From the drafting board to the workshop floor, we embarked on a journey that would lead us to design the nose cone, rear shroud, and a host of other parts, each with its unique challenge. Step by step, we worked to bring the car to life, meticulously crafting each component and bringing it all together, piece by piece. Soon, our attention shifted to in-house manufacturing of the nose cone, side panels, and rear shroud. We carefully applied glass fiber and polystyrene resin layers to make the nose cone. The process was labor-intensive, balancing my classes with manufacturing tasks, but the satisfaction of shaping our project's core made it all worthwhile.
Taking our creation to the competition site was a thrilling experience. While we didn't clinch the top spot, the lessons learned were invaluable. Judges and fellow teams showed us the power of simplicity in design, spurring us to refine and improve. In the competition's heat, I gained hands-on experience, engaging in machining and fine-tuning our car for the upcoming season.
As one chapter closed, a new one began – I was entrusted with the role of Mechanical Lead, a testament to my technical and leadership capabilities. From that point, the focus has been clear – building a car that's not only reliable but a testament to precision. I delved into every design detail, ensuring every nut and bolt served a purpose and assembling a team that thrived on technical prowess and expertise. Our journey took us through leaps and bounds – from optimizing designs and laying the groundwork for mathematical modeling using MATLAB to extensive testing to uncover any potential for improvement. The challenge of integrating electrical components with mechanical systems was ever-present, but it was a challenge we embraced head-on for our electric vehicle.
Though words might fall short, the passion and connection I've forged with the team are beyond measure. The symphony of motors and the sight of our creation in motion continue to drive my addiction to this electrifying journey. The video below gives a glimpse of what we do; please check it out!