Shell Eco-Marathon Chassis Development

Junior Frame Lead — Structural Design, Modeling, and Vehicle Dynamics Integration

ANSYS Mechanical SolidWorks MATLAB / Simulink Structural Optimization Lightweight Design Vehicle Structures

Tools & Methods CAD: SolidWorks · Simulation: ANSYS Mechanical · Dynamics: MATLAB / Simulink · Elements: Beam, shell, and solid · Approach: Iterative design + experimental correlation

Current Status Appointed Frame Lead · Concept layouts and packaging studies complete · Awaiting senior team review of legacy designs and FEA models · Road load model in MATLAB/Simulink under development

Leadership Role

For the current competition cycle I serve as Frame Lead for the Junior Team at JMU — responsible for chassis layout, structural validation, and integration with suspension, powertrain, and body systems. This role involves technical decision-making, design review with senior members, and establishing analysis workflows for future teams.

Early Concept Development

Below are early hand sketches exploring packaging and structural layout concepts prior to CAD development.

Concept Sketch — Initial Frame Layout

Concept Sketch — Packaging & Load Paths

Engineering Objectives

Deliver a lightweight, structurally efficient frame
Validate design using FEA and experimental data
Establish reliable load cases from real-world testing
Improve stiffness-to-mass ratio over previous designs
Ensure compatibility with body, drivetrain, and suspension systems

Planned Analysis & Modeling Scope

Torsional and bending stiffness evaluation
Braking and cornering load cases
Powertrain and driver mass distribution
Joint and mounting interface stress analysis
Road load modeling using experimental data

All assumptions, boundary conditions, and mesh strategies will be documented to ensure repeatability across team members and competition cycles.

Workflow

Review senior team chassis and FEA models
Develop validated load cases
Create baseline CAD geometry in SolidWorks
Simplify geometry for analysis
Run baseline FEA in ANSYS
Correlate with MATLAB/Simulink road load model
Iterate for mass and stiffness optimization
Finalize manufacturable design

Next Steps

Consult senior team on legacy design choices
Review historical FEA and test data
Complete first-pass road load model
Begin initial CAD chassis layout
Establish structural benchmarks

This page will be updated with CAD renders, FEA results, and validation data throughout the season.