CORNELL BAJA RACING:
Ergonomic Design and Manufacturing
CC
Fall 2019-May 2022
Cornell Baja SAE Racing is an engineering project team that annually designs, builds, and races an off-road vehicle to compete in the SAE Collegiate Baja Design Series.
Each year, our research moves through 3 stages of review before our design is finalized: Preliminary Review, Critical Review, and Final Review.
UX Techniques Used
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Competitive Analysis
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User Interviews
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User Persona
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Usability Testing and Iteration
My Role
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Ergonomics Designer
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CAD Designer
Tools Used
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Figma
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Microsoft Office
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Solidworks
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Adobe Illustrator
We are constantly modifying our older cars, so we can test new designs on prior years’ vehicles. I am a member of the Cornell Baja team and a member of the Ergonomics subteam.
The composites and ergonomics subteam designs and builds the seat, steering wheel, and body panels, with a focus on human centered design and materials testing. As an ergonomics subteam member, I participate in ergonomic research, manufacturing, and overall aesthetics of our car.
Below are some interfaces I worked on during my time on the team!
Fiberglass Seat Mold Process
Our offroad vehicle’s seat is manufactured in house. Our seat layup is made from a fiberglass layup. This layup is later waxed and used for a carbon fiber mold.
Layup Making Process
When making our exterior body panels, we coat the layers of composites sheets with epoxy and hardener mixture. We ensure safety and efficienvy by working in protective gear and in pairs.
Body Panel Manufacturing Process
Discomfort Survey Result: Example
Co-Creation Testing
We conduced co-creation testing using an old car seat to better understand lumbar support and space in our seat design. Participants were asked to place cushioning where they felt needed. This data was later included in our final seat design.
Hat Plug Design
This part was made from high density foam. It was CNC-ed, sanded down to a 100 grit, and then bondo-ed to ensure that there is no deformities. The plug was later used for thermoforming to create the hat mold.
Foam Plug for Fiberglass Layup
An ergonomically designed seat is first created in Solidworkds. Next, is CNC-ed in high density foamed and sanded for a smooth surface. Finally, it is sprayed with Duratec R Gray Surfacing Primer to be prepped for the second step in the seat making process.
Gear Shifter Design:
The gear shifter is an interface in the
car that helps the vehicle to change from 2WD to 4WD. Ideally, the gear
shifter is located on the right side of the driver and provides enough arm
space from the shifter to the driver’s body and inner frame when it changes
gears.
Design Requirement:
The gear shifter should be easily accessible for the driver, and prevent friction while grabbing, and minimize slipping when in use. It should also fit into ergonomic standards and be in accordance with the ergonomic sizing
for the 5th percentile female and 95th percentile male
Constraints:
• Eliminate T-bar design and use a circular design instead to better the curvature of the hand and prevent T-bar hitting driver’s leg
• Adjust sizing t into the 5th percentile female - 95th percentile male hands
• Reduce indentations and crevices to minimize friction and catching of the hands
Gear Shifter CAD
