Brakes and Pedal Box Design 2023

Led the design, manufacturing, and validation of the brakes and pedals for the 2023 Formula SAE car. Started brakes from square one since previously we had used off the shelf components for our calipers and rotors.

Using lap sim data and thermal models of the rotors developed in Ansys, I optimized the rotors for weight and performance. Similarly, I used driver foot size and strength measurements to inform the design and iteration of the pedal box. Combined, the pedals, brakes, and calipers were 64% lighter than the previous year.