Formula SAE Spool Mounts

A Formula SAE chassis subassembly supporting the differential spool and precise chain-tension adjustment.

Period: 2021–2023
Role: Mechanical designer, CU Boulder Formula SAE
Methods: SOLIDWORKS · FEA · Mechanical Design · Fabrication

A rendered Formula SAE differential spool mount assembly

01 / Challenge

Engineering Challenge

Package the rear spool and give the team a rigid, precise, and serviceable way to control chain tension within the existing chassis.

02 / Approach

Approach

I developed a bolted adjustment architecture, modeled the complete assembly, evaluated competing layouts, and used simulation to identify structural behavior before fabrication.

03 / Result

Results

The bolted approach was selected over the previous clamp concept for its rigidity, precision, and assembly advantages.

Key Outcomes

1major chassis subassembly

Owned the CAD for a major chassis subassembly
Compared architecture options through practical assembly criteria
Used FEA to inform geometry and communicate loading

Finite-element analysis result on the Formula SAE spool mount — Simulation used to understand the response of the mount structure.