March 2026 Blog

While the team experienced some delays in securing parameters for our electrical system, development of the car has continued steadily. Members have been learning and applying finite element analysis (FEA) to various components, ranging from the motor drive shaft to the wheel hub.

This month concluded with an exciting milestone: receiving our first CAD model from our battery supplier, Topattery. This will significantly support our progress as we move toward fabrication.

As more members become proficient with the various software platforms required to design and analyze the car, it has been impressive to see their growth. Students who began with a simple interest in cars are now developing strong skills in design, data analysis, and project management. This team continues to demonstrate the value of the FSAE experience.

Although the academic year is coming to a close, the team is still welcoming new members, especially those interested in helping with summer fabrication. All are welcome!
Powertrain:

We have selected our current and brake pressure sensors, allowing us to complete the preliminary design of the BSPD. With the battery CAD model now received, we will be finalizing our motor mounts this month.

We have also made progress in developing our motor shaft, which will be responsible for transmitting the motor’s torque to drive the car forward. The team has been consulting with UNB faculty to determine the best way to design the shaft to withstand loads over the car’s lifetime. Through this analysis, the team has developed a deeper understanding of how stress concentrations affect design and how to effectively mitigate them.

Electrical

This month, we have made progress on the high-voltage side. We sized our cables and received a sponsorship to obtain them for free. We also looked into the connections for the motors and the inverter.

On the low-voltage side, we have received confirmation that the IMD has been shipped, and we have purchased the position sensor for the acceleration pedal.

Dynamics

All suspension components that have been developed in CAD have begun undergoing static structural FEA. This is being used as an initial validation step while we continue iterating on the designs to optimize weight and make sure the components can withstand expected dynamic loading conditions. We have also reached out to several PhD candidates at UNB for consultation on dynamic FEA, which will be a huge help moving forward in validating our design and its feasibility

The outboard suspension geometry is largely finalized, and a complete 3D assembly model has been developed in SolidWorks. Work on the inboard suspension is progressing in parallel, with current focus on evaluating different rocker geometries for both the front and rear suspension.

The rocker plays a key role in translating wheel motion into spring and damper compression in an inboard suspension setup. We are exploring different rocker designs to achieve desired motion ratios, ensure near-linear response where possible, and package the system efficiently within the chassis. Considerations include rocker shape, pivot placement, load paths, and overall structural stiffness, as these directly affect suspension performance and adjustability (tuning).

The rear suspension bill of materials (BOM) is now nearing completion, with most major components identified and specified.

Chassis

In March the chassis team spent a good deal of time looking into confirming the steps in the manufacturing process. Livingston steel was confirmed as our steel tubing provider. For cutting and coping of the tubes, Sunny Corner will be providing the services, and they may help out with some welding as well.

We finally received the battery CAD from Topatry. We are currently working towards an effective solution to mount the chassis, making it easily accessible and also having a simple way to attach and detach from the car. Also, with the dimensions and orientation of the battery, we can continue to package all other components for the rear so that the rear of the chassis can be finalized.

The steering assembly is just about complete. We have decided on using two U-joints to allow the steering wheel to be adjusted in the longitudinal axis, depending on the driver. The final steps are to mount the steering assembly to the chassis frame. Along with the assembly, an ergonomic steering wheel design is almost complete and ready to be manufactured.