Three years on UVic's Formula SAE team in aerodynamics and composite structures, working across sidepods, vortex generators, rear wing elements, gooseneck mounting, and some undertray development.

UV24 molded carbon side panels:
Helped design and produce the molded side panels for the UV24 car. The panel surface was derived directly from the chassis geometry using SolidWorks surfacing, held at a 0.1 in offset from the frame so the bodywork followed the car closely without fouling it. From that surface I built a positive mold and produced the panels in wet layup woven carbon with vacuum bagging. The finished panels were lightweight, dimensionally accurate, and fully compliant with FSAE 2024 rules.

UV25 replacement bodywork mold:
When the existing bodywork mold was destroyed, the UV25 car was two weeks out from the 2025 competition with a $500 budget to solve it. Remachining was not possible in either the time or the money, so I worked with a team to rebuild the mold using a different manufacturing approach entirely.

Profiles were taken from the previous mold's CAD at 2 in spacing, laser cut flat, and mated to a profiled spine acting as a base plate, so the structure was self-jigging and the rib spacing came out accurate without manual alignment. A 3D printed nose piece handled the compound curvature at the tip where flat profiles could not. Longitudinal reinforcement used 2 in foam rated 16 to 20 MPa cut to profile, with 6 in support profiles, sized to carry vacuum pressure without crushing during layup.

Result: The rebuilt mold reproduced the profile of the original machined mold, survived layup and vacuum with no damage, and came in at roughly 75 percent less cost and time than the original. UV25 attended competition with molded bodywork.

Across both cars the underlying work was the same: turning aero intent into parts that hold their designed shape under load, with attention to load paths, attachment strategy, and stiffness so an element does not deflect, crack, or work loose during a run. Attachment is where student aero packages usually fail, since the aerodynamic surface gets the design attention and the brackets get whatever is left over.