Manufacturing Mania!

While winter quarter wound down, our team did the opposite, staying busy with working on the car and finals. 

Unsprung focused on wheel package manufacturing this month and is almost done! The tripod housing, one of the more complex parts, is finalized, and they are now wrapping up other components. For example, the brake rotors and brake hats are being fit together, as seen in the test image below!

Manufacturing has made huge strides this month. The drivetrain is making headway as tabs are being assembled. Additionally, the brake and accelerator pedals were waterjetted and are almost finished. They will be mounted to the carbon fiber floor shortly, allowing the car to be driven and controlled!

A lot of painting was also done this month, leading to many opportunities for team bonding! The pedals and suspension arms were painted in FRUCD gold to match our school and branding. Controls also painted their components, and we look forward to seeing the gold on the track!

Accumulator finished their subpack manufacturing, which are key components of the battery packs and hold individual battery cells. The subpacks will eventually be connected for the system to get a total peak voltage of 504 V. This year, there are a total of 72 cells per subpack that must be wire bonded together, so many thanks to Hesse Mechatronics for aiding us in making this ultrasonic welding process happen! 

Moreover, the accumulator lid and power electronic floors were bent and test fitted this month. The enclosure also got painted. 

Electrical has worked closely with the accumulator subteam this March, so thanks to both teams for their work! The BMS boards have been assembled and they are now supporting accumulator with electronics, first, planning out the wiring harness. 

Composites worked hard this month manufacturing carbonfiber pieces of the car including the endplates, nosecone, and floor. Using new manufacturing techniques and methods, they were able to save a lot of time and weight. For the first time in our team’s history our members have assembled a first rear wing for the car, wrapping up by bonding the wing airfoils!  

Chassis was also productive this month as the chassis got powder coated and polyfiber was attached to the chassis. Even more painting was done by Chassis as well, as they sprayed the body of the car black. The painting we completed this month speaks to how much progress our team has made in manufacturing, and we can’t wait to see more! 

In non-manufacturing news, Tommy Lo, one of FRUCD’s founding members, was kind enough to invite us to watch him race at Sonoma Raceway this month. Our team had so much fun socializing, learning from him, and getting to watch cars on track. Thanks so much to Tommy Lo and everyone who attended the track day!