Half Shaft Plungers

A plunging system inside the axles/half shafts of the vehicle ensure that the tripod bearings maintain full contact
By installing a plunger with a spring, the continuous contact can help lead to reducing unsprung mass on the stub shaft end

Machined plastic filled rod inside the half shafts, roll pin holes to keep the end stop in place, and assembled the spring with the plunger
Installed in the vehicle through taking off suspension control arms, rubber boots, and half shaft covers
Removed and reinstalled safety wire to ensure complete rules compliance

R&D task demonstrated a possible net weight reduction if the stub shafts were manufactured to be shorter
A problem in the extra length of the half shafts meant the plunging system was not completely functional
Identified future improvements, such as stiffening spring and further reducing half shaft length

Designed a topologically optimized sprocket adapter and set of sprockets for UWFE's driveline subsystem

Designed and manufactured an FSAE rules legal scatter guard to enclose the EMRAX 228

Designed and manufactured an FSAE rules legal scatter guard for the driveline subsystem

Trace It is a hands on target practice toy, utilizing two motors and an infrared gun

An EV3 robot that can capture videos and images using tracking and keyframes

Mechanical designs and rapid prototyping at Curtiss-Wright

Performed analysis on UWFE 2026 vehicle to determine appropriate gear ratios

Ensuring critical rotation and mounting of the custom limited slip differential

I created four pairs of chassis harness mounts to ensure the driver has a legal harness for Formula SAE Electric events.

Created a laser cut jig in order to accurately position the front enclosure mount within 2 millimeters laterally and longitudinally

Fully custom made LED Dice PCB

I constructed a dynamometer out of TETRIX to measure the speed and torque characteristics of a TT motor

Andy Lai

Andy Lai

Andy Lai