BAJA Off-Road
-
Design a suspension system for a completely new frame based on stringent SAE regulation
Develop a modular, parametric assembly that streamlines collaborative iteration, enabling precise optimization of critical handling variables such as toe and camber.
Optimize manufacturability and efficiency by designing components for seamless fabrication and generating detailed, itemized bills of materials to enhance production workflow.
-
Head of Brakes, Suspension, and Steering Systems – Led the design and development of high-performance vehicle subsystems, delegating tasks across the team and ensuring design integrity through FEA verification. Coordinated with manufacturing experts to implement Design for Manufacturability (DFM) principles, optimizing components for efficient production and assembly.
-
October 2024-Present
-
Onshape Enterprise
Computer-aided Manufacturing for 3-axis milling
Finite element analysis
Fusion 360
Frame tooling
Sheet metal manufacturing
Metalworking
Siemens NX Generative Design
-
Engineered a fully parametric off-road racing vehicle assembly, enabling real-time animation and automatic recalculations of suspension and steering geometry based on toe, camber, and compression variables. This streamlined iteration, slashing design time and ensuring peak performance. Led the front hub carrier design, a component machined with precision 3-axis HAAS milling to withstand upwards of 15.6kN of force while holding the front wheels and allowing for high-range at high speeds. Led cost-saving initiatives, cutting $3,000 in expenses by optimizing manufacturability and fabricating parts in-house with CNC tooling.
Design Process
Originally, BAJA SAE used drawings to coordinate frame and suspension geometry. I redesigned all Brake, Suspension, and Steering systems to be fully parametric and modular within a master assembly. This enabled fit testing before manufacturing, saving time and resources. The complete geometry also allowed us to analyze toe and camber adjustments, automatically outputting dimensions based on our desired performance settings. Additionally, the master assembly generated a fully automated bill of materials, streamlining production.
2024
Season
2025
Season - my design
A key aspect of my design approach is ensuring that all components dynamically adapt to performance requirements. For example, the rear control arm in the suspension system is fully variable-controlled. By inputting a camber angle—the tilt of the wheel relative to the vehicle’s vertical axis—the control arm automatically adjusts its length to maintain proper alignment with the frame members. This ensures precise geometry without manual recalculations, improving both accuracy and efficiency in the design process.
Rear
Steering
Front
Hub Carrier project
In previous years, we used a MacPherson strut for the front suspension—a system that utilizes the top of a telescopic damper as the upper steering pivot. While common in road cars, it is optimized for high-speed highway travel rather than off-road racing. A more effective alternative is a double wishbone system. However, since our axles were designed for a MacPherson strut, a compatible hub carrier for a wishbone setup was not available off the shelf. To address this, I led an effort to mill our own custom hub carriers, ensuring compatibility and improved off-road performance.
MacPherson suspension system
left-click/use 2 fingers to Interact with the carrier
During the initial design phase, structural finite element analysis (FEA) was conducted to ensure the part could withstand a reasonable load case of 5 kN. The final component achieves a safety factor of 1.5. Results were cross-validated using both ANSYS and SolidWorks.
Design reviews and multiple perspectives are among the best ways to maximize a part's likelihood of success. To support this process, I created detailed documentation and task spreadsheets outlining each milling phase and the corresponding operations. I then coordinated with colleagues to code appropriate tooling. Through extensive design reviews and simulations, we ensured the design was optimized for manufacturability.
We are currently in the final stages of CAM reviews, and will soon begin production of 3 hub carriers for use on the 2025 BAJA car. The carriers will be manufactured on a HAAS 3-axis mill out of Aluminum 6061.
