Student Projects
NUsolar Solar Car Aeroshell

SWEethearts Gala group photo

Project Manager

Ethan Flood, NUsolar

Amount Requested

$5,000

Summary

In our 2020-2021 Murphy Project application, we applied for and successfully received funding to perform research, testing, and analysis on the carbon fiber components of our next vehicle, SC8, also known as Bastet. We have now completed this phase of the project, and are ready to manufacture Bastet’s carbon fiber aeroshell. This process will involve laying the carbon fiber into fiberglass molds to create a shape that is optimal for reducing drag, and thus substantially improving the vehicle’s performance. Carbon fiber molding is extremely common in the automotive industry, as well as many other engineering industries. Therefore, forming the aeroshell is a great project for new members to work on to learn a skill that will help to prepare them for their future careers. Unfortunately, carbon fiber is extremely cost prohibitive. Funding through the Murphy Grant would greatly help to provide this opportunity, which is otherwise inaccessible to students at Northwestern, to our members.

Planned Activities/Investments

The aeroshell design process includes multiple steps and materials, and provides several opportunities for our members to learn new aspects of manufacturing. The first step in the process is to design an aeroshell using 3D modeling software. During the modeling phase, our mechanical team honed their SolidWorks skills by creating several possible aeroshell designs and running multiple simulations to ensure that the one chosen meets all safety requirements and has optimal aerodynamic qualities. Our team then used a router to cut sheets of foam, and then glued them together in layers to make a male “plug” mold in the shape of the aeroshell. Next, they will use the foam mold to create a female mold out of fiberglass. Finally, with carbon fiber we hope to obtain using Murphy Grant funds, our members will apply a carbon fiber layup to the fiberglass mold to create the final aeroshell. This project provides members of our mechanical sub-team, as well as any members of our other sub-teams with an interest in learning about the manufacturing process, with hands-on manufacturing experience. Since it involves numerous steps, it is a great way to give new members their own “mini-projects” and get them in the shop and learning right away.

Impact

Our project will benefit Northwestern students by providing them with an opportunity to gain industry applicable skills through hands-on learning they do not receive in the classroom. We provide our forty-plus members with an outlet to demonstrate their passion for environmental awareness and gain valuable work-related experience in a space that immerses them in the field of automotive technology. The impact of our organization is evident in the feedback we receive from our members, the career outcomes of our members, and the willingness of alumni to give back to our organization. We use pre- and post-quarter surveys to get feedback from our members on what they’re interested in learning about and how we can improve going forward. The ultimate goal of NUsolar is to provide an experience that benefits our members, and hearing their opinions is of paramount importance in achieving this. Our members are very successful post-grad. Our alumni land at top companies including General Motors, Google, McKinsey & Company, and SpaceX in every field from automotive design to consulting. Perhaps one of the strongest indicators of the impact NUsolar has is the willingness of alumni to give back, whether through monetary donations, networking opportunities, or other means. Our alumni often tell us what a formative part of their college experience NUsolar was, and we’re devoted to continuing to provide that experience to future generations of Northwestern students. 

Deliverables

The main deliverable for our project is the aeroshell of our car. We work throughout the year to design, build, and test it in preparation for the Formula Sun Grand Prix in the summer. Additionally, we will be able to deliver new member and current member training for our mechanical sub-team and other team members interested in manufacturing with this project. We also put together updates for our faculty chairs every quarter.

Sustainability

In addition to the Murphy Grant, NUsolar receives funding through donations to our yearly Catalyzer campaign, as well as several other grants awarded by entities within Northwestern University and external organizations. The Catalyzer campaign is run in association with Northwestern University and focuses on donations from individuals, including alumni.

Previous Projects

Using the funding we received from the Murphy Society from our 2020-2021 application, NUsolar conducted an extensive investigation into the processing and performance of carbon fiber, a high-performance material crucial for our next-generation solar vehicle, SC8. Our activities included acquiring raw carbon fiber material, manufacturing reusable composite curing equipment, and accessing characterization equipment in Northwestern research facilities.

Our mechanical team of over 20 undergraduate students led this project, focusing on the fabrication of scale models and conducting rigorous materials testing. This hands-on experience allowed us to gather essential data, which we used to develop clear guidelines for working with carbon fiber in our structural components. By running development and analysis in parallel, we rapidly created a comprehensive manufacturing plan and materials performance database.

The achievements from last year’s project were significant. We successfully fabricated scale models, tested the performance of carbon fiber, routed the components for our top shell mold, and minimized errors during our fabrication process. This project provided invaluable educational experiences, enhancing students' skills in mechanical design, materials science, leadership, and project management. Moreover, the knowledge and equipment developed during this project have laid a strong foundation for the full-scale production of our carbon fiber aeroshell and will continue to benefit our team’s future vehicle designs.

Budget Overview

 In our 2023-2024 Murphy Project application, we applied and successfully received funding for the foam necessary to create a mold for the SC8 aeroshell. We have successfully routed the top shell mold components and are now manufacturing the bottom shell components. After the two mold components are finished, the following needs to be done:

  • Glue the foam components to form the molds
  • Prepare the mold surface with surface epoxy, primer, and mold release
  • Perform the carbon fiber layup. This requires large tow carbon fiber fabric, epoxy, vacuum bagging, breather material, sealant, and a vacuum pump
  • Layup the carbon fiber Nomex panels for the aeroshell ribs
  • Make attachments and integrate the aeroshell into the vehicle assembly

This project will emphasize the hands-on experience of mechanical design manufacturing. In this process, we will emphasize the importance of safe manufacturing procedures, and understanding the discrepancy between designed components and manufactured components, which manifests through design tolerances inherent to our manufacturing processes. With funding from the Murphy Society, our team will be able to acquire the necessary materials to finish SC8.

This budget is focused on the acquisition of composites, which ensure a light and sturdy aeroshell for our solar car.

  • Carbon Fiber (Large Tow): $4,350
  • Vacuum Bagging: $290
  • Sealant: $350

Total Budget Amount: $4,990

Faculty Adviser/Department

Jeremy Keys/Electrical and Computer Engineering