For the 2026 Shell Eco-Marathon, I oversaw the redesign of the steering and braking systems for a student-led hydrogen fuel cell vehicle club at Swarthmore. The main priority for the redesign from the previous version was to make all components lighter. I began the project by developing a Fusion 360 Digital Twin. This model was critical in reconciling physical construction discrepancies with digital dimensions, ultimately serving as the foundational CAD reference for the entire team’s sub-projects.
The existing carbon fiber tubes introduced spatial constraints for the steering rack and pinion. So I used generative design to optimize the placement of the rack and pinion. This approach allowed me to develop 3D-printed mounts that maximized structural integrity while minimizing mass. Beyond the internal mechanics, I designed an ergonomic, angle-adjustable vertical steering wheel that integrated throttle, horn, and brake controls for rapid driver access. I further supported the assembly by machining custom tie rods to achieve a tighter steering radius, ensuring the vehicle met both performance requirements and the need for modular, track-side repairability.
My work on the braking system involved adapting simultaneous-hydraulic ATV calipers into a centralized foot-pedal configuration. The primary challenge lay in the precision CNC machining of aluminum caliper mounts, which required navigating complex angles and strict geometric tolerances to ensure proper wheel clearance. This project provided deep technical experience in hydraulic integration and more advanced fabrication than I’m used to, balancing the high-stakes requirements of safety-critical systems with the efficiency goals of a competitive eco-marathon vehicle.
