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Summary
Designed and built the structure to support 95 steel tubes for tack welding, leveraging 3D prints & laser cut MDF to keep cost below $200 to produce a dimensional accurate solar car chassis critical for integration with exterior panel mounting, suspension hardpoints, and electrical.
Objective
Used low-cost materials that wouldn't compromise on DFMA or rigidity during installation & welding
Identified hardpoints where ±0.5mm accuracy was critical, establishing datum features to build around
Discussed design improvements with professional welders, optimizing tool and working clearance
Reinforced MDF fixture planes using interlocking lap joints and providing the necessary rigidity to the jig
3D prints to align tubes with complex bends for rollcage
Wooden MDF Panels interlocked to provide rigid tube alignment
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