Berkeley Formula SAE designs, builds, and competes with a single seat formula style race car as part of an international engineering competition. The team operates like a small engineering organization, with subsystem ownership, design reviews, manufacturing timelines, and validation testing leading up to competition.
I worked as a Suspension Engineer, contributing to the design, manufacturing, and validation of steering and suspension related components. My work focused on designing parts and tooling that could be reliably manufactured, assembled, and tested within tight packaging and schedule constraints.
I have worked on:
Steering and suspension components
Shock dyno hardware and test fixtures
Welding jigs for suspension and chassis related assemblies
These systems required close coordination with chassis and manufacturing subteams to ensure geometric accuracy, structural integrity, and serviceability.
My approach emphasized design for manufacturing and validation. Components were designed with GD&T driven drawings to control critical geometry, especially for welded assemblies. I designed and manufactured welding jigs to ensure repeatable alignment during fabrication. Test fixtures and shock dyno hardware were developed with load cells to collect meaningful data and support suspension validation. Design decisions were iterated based on manufacturing feedback and testing results rather than theoretical performance alone.