FSAE Electric Club: Master Switch Enclosure

Skills: [SolidWorks, 3D Printing, Rapid Prototyping, Design Engineering]

This was my main project for the Formula SAE Elctric Racing club. It was a 3D printed PLA enclosure for the high and low voltage electrical systems’ master switches. The enclosure was designed in SolidWorks and fabricated with 3D printing. It was attached to the car for testing before the FSAE competition was canceled and everyone was sent home due to COVID-19. The enclosure included mounting points for the two switches (the two large circled on the front), the power indicator lights, and a separate detachable module on the bottom for two banana jacks.

The enclosure was designed to take up as little space as possible to have a minimal impact on the car body's aerodynamics while still completely enclosing the electrical components. The FSAE Rulebook mandated that the TSMP (Tractive System Measurement Points) mount, seen here at the bottom of the enclosure, had to be separated by a physical barrier from the rest of the components. The TSMP mount also needed to be insulated and waterproofed, a requirement that did not apply to the rest of the enclosure. Because of this I decided to design it as a separate module that would be waterproofed before being permanently glued into place.