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Sprint Goals:

  • Get members familiar with surface modelling tools in SolidWorks, applying these tools to basic shapes (i.e. a canopy)

  • Get members accustomed to designing relevant components within the Aerobody and critiquing each other’s work

  • Learning to make your own design decisions along with applying feedback from peers and leads

  • Working within deadlines, having made progress with each review

  • Documenting progress using a design log

Topics to be Covered:

  • Concept Sketches → Design → CFD Simulations

  • Solidworks Computer Aided Design (Surface Modelling)

  • Researching Material and Composites Manufacturing Techniques (Thermoforming)

Sprint Introduction:

For this design sprint, you are tasked with designing a solar car canopy (the part of the car that surrounds the drivers head). Typically, this is a removable piece of the car that allows the driver easy access to the cockpit.

image-20240905-130541.png

The canopy you design can serve as inspiration for the canopy that you put on your aerobody for design sprint #3. It is up you on how complex/unique you want your canopy design to be!

Some design considerations:

Aerodynamic performance: how aerodynamic is your canopy, and what shape is it taking? Ideally, it shouldn’t be as simple as a cube as that would be an oversimplification of the sprint and not teach you much about surface modelling.

Size: Will your canopy fit around the driver’s head and the car chassis?

Practicality: Does your design make sense? The canopy consists of both a solid composite portion, and a transparent windshield. What do you think is the best use of the canopy area?

image-20240905-133202.png

While these are suggestions, you are encouraged to take these factors into consideration when designing your canopy, as you will be asked to explain your decision making process during the design review.

DIMENSION TYPE

AVERAGE RANGE

Length

10cm - 14cm

Width

5cm - 7cm

Height

2.5cm - 5cm

These are just general guidelines, if you wish to branch away from this, as long as your design is ergonomic, go for it!

Timeline:

Please feel free to set up independent reviews with leads or other members. You are not limited to the scheduled reviews.

Week 1:

Begin with conceptual design. Decide how you want to solve the design while keeping in mind constraints and criteria. After finalizing your conceptual design, you should advance to some CAD (the exciting part)!

(tick) Bring To Review: An in-progress first CAD iteration within SolidWorks, plus any questions/problems you may be having with surface modelling.

Week 2:

By week three you should have more finalized CAD and should begin adding and perfecting more complex features.

(tick) Bring To Review: Completed first CAD iteration within SolidWorks → surface modelling

Week 3:

A completely finished CAD model should be ready, this should be exactly how you want the design to look like in real life. All dimensions and features should be accurate and modelled using proper techniques. You should also perform CFD simulations on your mouse. Although CFD sims are not too big a concern for computer mouses, they are very important for MSXV! By going through a CFD simulation you will learn how we are working on optimizing the shape of the aerobody to improve our coefficient of drag and overall flow separation.

(tick) Bring To Review: Final CAD Design and Completed CFD sim within Solidworks

Additional:

Once you have finished working on your mouse design, start researching about manufacturing methods. For instance, you may want to start looking into thermoforming. If you were to manufacture this mouse, how possibly can you do so using thermoforming?

Challenge:

If you are up for a challenge attempt Design Sprint 2, where you will be designing your own aerobody!

Design Log:

Keep a design log for all progress! A design log will help organize all content for presentation.

Sample Design Logs:

https://docs.google.com/presentation/d/10ylmWYR_Er4OoCQ5UJIiymEIGTLgjv72pMDDRAr9HMI/edit?usp=sharing

Resources:

  1. Surface Modelling *Highly suggest going through this session as it goes over all the basics you need*

  2. https://youtu.be/lnJTfrqYfMU *If you are looking for a tutorial to follow as practice before beginning your own, this video can help*

  3. /wiki/spaces/MFG/pages/1453817927 *For more information on thermoforming*

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