Project Snapshot
ROLE
Chassis subsystem member → Chassis lead
PERIOD
2016–2017
TEAM
Baja SAE UNAM / Puma Off Road
COMPETITIONS
BAJA SAE Illinois 2017 · BAJA SAE Mexico 2017
SCOPE
Chassis design, fabrication, MIG welding and full-vehicle integration
TOOLS & METHODS
SolidWorks · Altair HyperWorks · Tube fabrication · MIG welding · Laser cutting · Vehicle assembly
01 / OVERVIEW
Baja SAE UNAM / Puma Off Road was my first major hands-on engineering project and the point where I became deeply interested in mechanical design, manufacturing and physical systems integration. I started as a chassis subsystem member and later became chassis lead, contributing to the manufacturing of two tubular chassis and fully designing the second one using SolidWorks and Altair HyperWorks.
02 / ENGINEERING CHALLENGE
The chassis design had to comply with strict Baja SAE regulations involving geometry, node positioning, material selection, stiffness, driver safety and tube bending constraints. At the same time, the chassis had to integrate with suspension, drivetrain, brakes, steering, CVT layout and full-vehicle assembly requirements. This made the project a real system-integration problem, not only a CAD exercise.
03 / DESIGN & SIMULATION
CAD decisions grounded in vehicle geometry
The second chassis was developed in SolidWorks and supported with Altair HyperWorks. The design was created in parallel with suspension requirements such as camber, toe and caster, while also considering drivetrain mounting points, brake system layout and manufacturability.
04 / MANUFACTURING & ASSEMBLY
From tube stock to full vehicle
The project involved extensive hands-on manufacturing: tube cutting, bending, notching, laser-cut references, MIG welding, lathe and milling support, fiberglass bodywork and full-vehicle assembly. I personally performed a significant portion of the MIG welding on the second prototype and supported other subsystems during integration.
05 / TESTING & OUTCOME
Validation through impact, iteration and endurance
What this project demonstrates
• Mechanical design under constraints
• Design for manufacturability
• Welding and fabrication
• Vehicle-level system integration
• Structural thinking
• Troubleshooting
• Hands-on ownership from CAD to physical testing
Image gallery
CAD MODEL
CHASSIS MANUFACTURING
ROBUSTNESS CHECK
VEHICLE ASSEMBLY
FINAL PROTOTYPE