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.
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 |
|---|---|
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  | 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)!
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.
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 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!
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:
Surface Modelling *Highly suggest going through this session as it goes over all the basics you need*
/wiki/spaces/MFG/pages/1453817927 *For more information on thermoforming*