Excalibur: Solar Vehicle

SYSTEM OVERVIEW

Excalibur is a road-legal solar vehicle designed for long-duration endurance racing. The chassis and roll cage must meet strict safety, weight, and manufacturability constraints while integrating with suspension, powertrain, and composite body panels. Designed for the American Solar Challenge—a multi-day, 1,500-2,000 mile cross-country endurance rally across North America.

MY CONTRIBUTIONS

• 01

  Designed a preliminary roll cage for the 10th Gen vehicle using SolidWorks and ANSYS, targeting a 1.4 safety factor under required load cases

• 02

  Performed structural simulations to evaluate tube sizing, load paths, and joint behavior

• 03

  Designed roll cage and occupant cell attachment points, including composite panel insert concepts

• 04

  Conducted hand calculations and simulation validation for panel strength and mounting interfaces

• 05

  Supported material trade studies for tubing and mounts, evaluating 4130 steel vs. 5052 aluminum

RESULTS

• Delivered a simulation-validated preliminary roll cage design meeting safety targets

• Established attachment and load-transfer strategies for composite body integration

• Modifications to car for race efficiency at FSGP 2024