Exteriors Design Sprint 1

Owned by Liam Ramlogan
Last updated: Oct 10, 2024
4 min read

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 “bubble” 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-20240906-203513.png
The canopy on MSXV. Notice the canopy (purple) is separate from the windshield (clear).

 

 

image-20240905-130541.png
UMichigan solar car’s Astrum, with a bubble canopy

 

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 (i.e. how much windshield vs. canopy should you have)?

 

 

 

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

DIMENSION TYPE

AVERAGE RANGE

Length (top to bottom)

 

 

170cm - 180cm

Width (left to right)

65cm - 85cm

This width should include the filleted edge on the bottom of the canopy (the edge in contact with the roof of the car)

Height

 

40-50cm

 

 

 

Timeline:

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

 

While this sprint will be introduced before the Surface Modelling 101 session, you are welcome to start working on it and learn as you go. There are various surface modelling resources that can be found both on our confluence (linked below) and online.

The purpose of this first sprint is to get you more familiarized with surface modelling tools, and it will not be as “formal” as the next two sprints. The timeline should be taken as a guideline, and you should work at your own pace.

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)!

Bring To Review: A completed first CAD iteration within SolidWorks, plus any questions/problems you may be having with surface modelling.

Note: your first iteration should not be your last! We expect you to bring any questions you may have to the design review, however we acknowledge that this is an easier sprint, and should not take as long as the next two.

Week 2:

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 be able to justify your design decisions to us, and walk us through your design process.

Bring To Review: Final CAD Design

Additional:

Once you have finished working on your canopy design, start researching manufacturing methods. How can we manufacture a canopy for the car, keeping in mind part of it needs to be clear?

Challenge:

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

Battery Box Thermal Analysis - Design Log

Resources:

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

  2. https://uwmidsun.atlassian.net/wiki/spaces/MFG/pages/1453817927 *For more information on thermoforming*