Mechanical DesignVehicle DynamicsStudent Engineering
SAE BAJA Suspension System Design
Led end-to-end design, analysis, and fabrication of a full off-road vehicle suspension system as Suspension Lead.
SolidWorksANSYSHand CalculationsDFMEADFMGD&T
At a Glance
Role: Suspension Lead
Team Size: 20
Timeframe: Aug 2019 – May 2021
100% custom-designed suspension system
Multiple critical components validated via FEA
Zero major suspension failures during testing phase
Problem
Design a robust, manufacturable suspension system for an off-road BAJA vehicle capable of withstanding high-impact loads, rough terrain, and endurance racing conditions while meeting SAE BAJA rules and tight manufacturing constraints.
Constraints
- Strict SAE BAJA competition rules and safety requirements
- High-impact and fatigue loading from off-road terrain
- Limited manufacturing resources and student workshop capabilities
- Weight minimization without compromising durability
- Tight build schedule aligned with competition deadlines
My Contribution
- 1Developed suspension geometry concepts and selected a double wishbone configuration based on performance and manufacturability
- 2Performed hand calculations to estimate loads, stress ranges, and factor of safety
- 3Modeled all suspension components in SolidWorks with proper GD&T and tolerances
- 4Validated designs using FEA in ANSYS for stress, fatigue, and impact loading
- 5Iterated designs based on analysis results, manufacturability, and assembly feedback
What I Built
- Designed critical suspension components including wishbone arms, knuckle, spindle, and mounting brackets
- Performed static and fatigue FEA on suspension components to validate strength and durability
- Executed tolerance stack-ups to ensure proper fit-up during assembly
- Created DFMEA documents to identify and mitigate potential failure modes
- Applied DFM principles to simplify machining, welding, and fixturing
- Coordinated fabrication of machined and welded components and supported assembly sequencing
Testing & Validation
- Bench-validated suspension components through fit-up and assembly checks
- Inspected fabricated parts against CAD tolerances
- Observed suspension performance during vehicle testing and shakedown runs
- Incorporated feedback from physical testing into design refinements
Results
- Delivered a fully functional suspension system from concept through fabrication
- Achieved structurally sound designs meeting strength and durability requirements
- Improved manufacturability and reduced rework through early DFMEA and DFM analysis
- Successfully integrated suspension system into final BAJA vehicle assembly
Gallery
Lessons Learned
Designing for manufacturability early prevents costly rework later
FEA is only as good as load assumptions and boundary conditions
Clear documentation (DFMEA, drawings) is critical for team-scale builds
Iterative testing and design refinement are essential for real-world durability