Shell Eco-Marathon Project

Senior Project Final Report

(T132)
PREPARED BY THE BODY GROUP
ABDALLAH AL-SAFFAR - 200873620
ALI DUWAIL - 200860760
MOHAMED LARADJI – 200929730

ADVISERS
DR. MOBEEN SHAUKAT
DR. ZUHAIR GASEM
Table of Contents
Introducton.................................................................................................................................................3
Problem Statement.....................................................................................................................................3
Benchmarking..............................................................................................................................................5
Vehicle Specifcatono..............................................................................................................................5
Remmi Team........................................................................................................................................5
Eco Veiculo..........................................................................................................................................6
Proto INSA Club...................................................................................................................................7
UMH Team...........................................................................................................................................8
Summary of Benchmarking Data.............................................................................................................8
Manufacturing Method...........................................................................................................................9
Seeraj Team.......................................................................................................................................10
Panther Rage Team...........................................................................................................................10
Material.................................................................................................................................................14
Car Shape Deoign.......................................................................................................................................14
Preliminary Car Specifcatono and Drawing..........................................................................................14
Updated Car Specifcatono and 3D CAD Model.....................................................................................17
Final Car Model......................................................................................................................................21
Propooed Method of Aooembly.............................................................................................................24
Material Selecton.....................................................................................................................................27
Materialo Reoearch................................................................................................................................27
Reinforcement...................................................................................................................................27
Matrix................................................................................................................................................27
Preprego.............................................................................................................................................28
Material Selecton Parametero..............................................................................................................28
Material Choice.....................................................................................................................................28
Supplier.................................................................................................................................................29
Manufacturing Reoearch...........................................................................................................................30
Manufacturing Methodo........................................................................................................................30
Prepreg Lay-Up..................................................................................................................................30
Wet Lay-Up........................................................................................................................................31
Coot Eotmaton..........................................................................................................................................32

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 Material Coot.........................................................................................................................................32
Other Cooto............................................................................................................................................32
Aerodynamico Analyoio of the Car Body....................................................................................................35
Summary of Reoulto...............................................................................................................................35
Finite Element Model............................................................................................................................35
Paper Prototype........................................................................................................................................39
Working Prototype....................................................................................................................................43
Manufacturing Teotng..........................................................................................................................43
Engine Cover Part..................................................................................................................................43
Mold Manufacturing..........................................................................................................................43
Laying the Fiberglaoo..........................................................................................................................47
Driver Cover Part...................................................................................................................................50
Aooembly onto the Chaooio....................................................................................................................52
Remaining Taoko to Be Done.....................................................................................................................59
Concluoion.................................................................................................................................................59
Appendix A – Summary of Meetng with Mr. Berrimi of Seeraj (Berrimi)..................................................60
Worko Cited...............................................................................................................................................61

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Introduction
The Shell Eco-Marathon io a competton in which teamo compete to produce the moot fuel efcient
caro. Many teamo all over the world take part in thio recurring event, which occuro in three diferent
regiono: the Americao, Europe, and Aoia. There are two main categorieo of partcipatng vehicleo in the
Shell Eco-Marathon, which are the Prototype and the UrbanConcept. In thio project, a Prototype car will
be made. In the Prototype category, there are very litle reotrictono on the car, and almoot all of the
reotrictono that do exiot are oolely there to enoure the oafety of the people taking part in the event. In
additon, Prototype caro need not be practcal.

The project team wao divided into three groupo: the body group, the chaooio group, and the powertrain
group. The body group wao aooigned the body ohell and the interior. The chaooio group wao aooigned the
chaooio frame, and the braking and oteering oyotem. The powertrain group wao aooigned the powertrain
of the car. The following progreoo report diocuooeo the work that wao done by the body group in
oemeoter 132.

Problem Statement
The aim of the project io to deoign a car that io ao efcient ao poooible, defned by the diotance that the
car can travel on a certain amount of fuel. Every oyotem of the car ohould be optmiied to obtain that
goal. For the membero of the body group, there are mainly two aopecto that ohould be conoidered,
which are the aerodynamico of the vehicle ohape, and the weight of the vehicle, which io an aopect that
io ohared by all of the membero of the project. That io, the car needo to have a very low coefcient of
drag at the driving opeed, and a very low frontal area, both of which will reduce the drag force on the
car and thuo ohould reduce the amount of fuel needed to keep the vehicle moving. A omaller weight
would mean that leoo power io needed, which would mean that leoo fuel io needed, to accelerate the
vehicle to a given opeed. However, there are limito to the ohape and to the amount of weight reducton
poooible, and thooe are the limito enforced by the Shell Eco-Marathon ruleo. In additon, the body would
need to be large enough to contain the driver, the chaooio, the engine, and other componento that will
be fted into the car. The following table ohowo the engineering deoign opecifcatono for the body of the
car [ CITATION She \l 1033 ]:

Variable Requirement Target Units Restrictions

Drag Coefcient, Cd Ao low ao poooible 0.10 - *
2
Frontal Area, A Ao low ao poooible 0.30 m *
Mass, M Ao low ao poooible 10 kg The body ohell muot not deform under
the efect wind.
*The body oiie and ohape muot accommodate all the equipment in the car, and muot oatofy the
requiremento ohown in the next table.

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Dimension Restriction
Height (cm) Maximum Height < 100
Maximum Height < 1.25xTrack
Width (cm) Total Width ≤ 130
Length (cm) Total Length ≤ 350
Wheelbase (cm) Wheelbaoe ≥ 100 cm
Track Width (cm) Track Width ≥ 50 cm
Mass (kg) Driverleoo Maoo ≤ 140

Competton ruleo require that the driver wear a racing ouit and a racing helmet. In additon, the car
muot have a horn, a fve-point or oix-point oeatbelt and a fre extnguioher, all of which would have to be
oelected to oatofy the opecifc requiremento oet for each component. [ CITATION She \l 1033 ]

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Benchmarking
Before commencing on the deoign proceoo, the caro of the rival teamo that achieved top reoulto in the
Shell Eco Marathon compettono were benchmarked. All of the caro ourveyed were prototype caro. The
informaton wao obtained from the reopectve team weboiteo.

Vehicle Specifcations
The following oectono are organiied by team and vehicle. A oummary of moot of the informaton io given
at the end of thio oecton.

Remmi Team
Remmi Team io a group of otudento otudying at the Tampere Univeroity of Technology. They had oeveral
oucceooful caro, of which two were ourveyed. All informaton wao obtained from [CITATION Rem14 \l
1033 ].

Remmi 7 (2008-)
Thio appearo to be the current car of the team ao of 2014. The vehicle had a very oucceooful record, and
the car achieved a mileage of 2960 km/l at the Shell Eco-marathon Germany 2009, and 3306 km/l at the
Pioaralla Pioimmälle Nokia 2008. The car hao three wheelo, two front idler wheelo and one rear oteering
wheel. The body of the car io oeparate from the chaooio, and the body io made of carbon fber, while the
chaooio io a opace frame that io made of carbon fber and foam. The car io 280 cm in length, 60 cm in
width and 60 cm in height, and hao a wheelbaoe of 149 cm and a track width of 51 cm. The total weight
of the car without the driver io 33 kg. Ao for the aerodynamico of the car, it hao an impreooive drag
coefcient of 0.0871, and a frontal area of 0.247 m 2. The Michelin “Eco-Marathon Radial” treo were
uoed for the car.

Figure 1: Remmi Team's Remmi 7 vehicle is shown in this fguree

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Remmi 6c (2003-2007)
Thio wao Remmi Team’o previouo car, and wao uoed from 2003 to 2007. Like their current car, thio car
too had a very oucceooful record, achieving a mileage of 3036 km/l at the NOKIA Finland 2007, and an
amaiing 3646 km/l in the U.K. (the competton name wao not mentoned in the weboite). Thio car aloo
had three wheelo, but it had two front oteering wheelo and one rear idler wheel. Similar to the current
car, the body of the car wao oeparate from the chaooio, and the body wao made of carbon fber, while
the chaooio wao a opace frame that wao made of carbon fber and foam. The car wao 325 cm in length, 72
cm in width and 60 cm in height, which io bigger than the current car, and it had a wheelbaoe of 160 cm
and a track width of 55 cm. The total weight of the car without the driver wao about 38 kg. The car had
drag coefcient of 0.102, and a frontal area of 0.38 m 2. The car had the Michelin “Eco-Marathon Radial”
treo.

Figure 2: This fgure shows Remmi Team's rrevious car, the Remmi 6cce

Eco Veiculo
The Eco Veiculo team io a team compooed of one profeooor and a group of otudento, which are mainly
from the Departamento de Engenharia Mecânica da Faculdade de Ciênciao e Tecnologia da Univeroidade
de Coimbra. It io aloo a oucceooful team, albeit not ao much ao the Remmi Team. The informaton and the
fgure were obtained from [CITATION Eco141 \l 1033 ].

XC20
Thio appearo to be the current Eco Veículo car, and it hao achieved a mileage of 2568 km/l at the Shell
Eco Marathon Germany 2011. The body of the car, made from carbon fber with uoh-mounted
polycarbonate windowo, io oeparate from the chaooio, which io a TIG welded aluminum 6063-T5 alloy
tube opace frame. The car io 290.6 cm in length, 59.9 cm in width and 60.9 cm in height, and it hao a
wheelbaoe of 165.5 cm and a track width of 50 cm. The total weight of the car without the driver io 32
kg. The car had drag coefcient of 0.0995 at 30 km/h, and a frontal area of 0.26 m 2. The Michellin 45/75
R 16 (Radial) treo were the treo of choice for the car.

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 Figure 3: This fgure shows Eco Veiculo's XC20 care

Proto INSA Club

Proto INSA Club io a team from INSA Lyon (The Inottut Natonal deo Scienceo Appliquéeo de Lyon). Thio
team had a relatvely leoo oucceooful record compared to the previouo team, but it otll hao a quite
impreooive record. The weboite io in French, and thuo there might be oome inaccuracieo in the
informaton obtained due to poooible tranolaton erroro. All of the informaton wao obtained from
[CITATION Pro14 \l 1033 ].

EPIC (Current Car – Unknown Start Date)

The EPIC car io the current car of the Proto INSA Club, and it hao achieved a mileage of 1833 km/L in
2010 (The competton at which the record wao achieved wao not mentoned in the weboite.). The car io
300 cm in length, 66 cm in width, and 60 cm in height, and weigho a total of 32 kg without the driver.

Figure 4: The EPIC car is shown heree

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UMH Team
The UMH Team io a team of otudento from the Univeroidad Miguel Hernándei de Elche. They had many
vehicleo, and the one that wao ourveyed io the DATIL 2011-2012, preoumably uoed between 2011 and
2012. The following informaton and the fgure were obtained from [CITATION UMH14 \l 1033 ].

DATIL 2011-2012 (2011-2012)

The DATIL 2011-2012 car io a relatvely oucceooful car, and it achieved a record of 1455 km/L (No
competton informaton wao found). The car had three wheelo, of which two are the front idler wheelo
and one io the rear oteering wheel. The body of the car io oeparate from the chaooio and io made of
carbon fber material. The chaooio io a frame made of aluminum tubeo. The car io 320 cm in length, 60 cm
in width and 60 cm in height, and it hao a wheelbaoe of 160 cm and a track width of 51 cm. The total
weight of the car without the driver io 42 kg and the car had a frontal area of 0.31 m 2. The car had the
Michelin “Eco-Marathon Radial” treo.

Figure 5: The DATIL 2011-2012 vehicle is shown here in the Shell Eco Marathon evente

Summary of Benchmarking Data

The following three tableo ohow a comparioon between the caro that were ourveyed. The record ohown
in the tableo io the higheot achieved diotance per amount of fuel found for the reopectve vehicleo. The
daoheo repreoent informaton that wao not found.

Vehicle Team Record Number of Number of Steering

(km/L) Front Rear Wheels
Wheels
Remmi 7 Remmi Team 3306 2 1 Rear
Remmi 6c Remmi Team 3646 2 1 Front
XC20 Eco Veiculo 2568 - - -
EPIC Proto INSA Club 1833 - - -
DATIL 2011-2012 UMH 1455 2 1 Rear
Table 1: Thio table ohowo the vehicleo ourveyed, the reopectve teamo, the record achieved, and the
oteering arrangement.

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 Vehicle (Record) Team Length Width Height Wheelbas Track Width
e
Remmi 7 (3306) Remmi Team 280 60 60 149 51
Remmi 6c (3646) Remmi Team 325 72 60 160 55
XC20 (2568) Eco Veiculo 290.6 59.9 60.9 165.5 50
EPIC (1833) Proto INSA Club 300 66 60 - -
DATIL 2011-2012 (1455) UMH 320 60 60 160 51
Average - 303.1 63.6 60.2 158.6 51.8
Table 2: Thio table ohowo the dimenoiono of the diferent vehicleo that were ourveyed. Note that the
record diotance io in km/L, and all the dimenoiono are in cm.

Vehicle (Record) Team Weight Body Drag Coefcient Frontal

(kg) Material Area (m2)
Remmi 7 (3306) Remmi Team 33 Separate 0.0871 0.247
Carbon
Fiber
Remmi 6c (3646) Remmi Team 38 Separate 0.102 0.38
Carbon
Fiber
XC20 (2568) Eco Veiculo 32 Separate 0.0995@30km/h 0.260
Carbon
Fiber
EPIC (1833) Proto INSA - Monocoqu - -
Club e Carbon
Fiber
DATIL 2011-2012 (1455) UMH 42 Separate - 0.310
Carbon
Fiber
Average - 36.3 - 0.299
Table 3: Thio table ohowo the weight, the material choice for the body, and the aerodynamic properteo
that were found for the vehicleo ourveyed.

Manufacturing Method
Ao the material of choice for the vehicle wao a compooite material, which may require opecial proceooeo
to manufacture, the manufacturing methodo of two teamo were ourveyed: the Seeraj team of the King
Fahd Univeroity of Petroleum and Mineralo, and the Panther Rage team of the Florida Internatonal
Univeroity. The following two oectono detail the manufacturing proceooeo that were uoed by the two
teamo. Note that the material of choice for the Seeraj team wao carbon fber, while for the Panther Rage
team it wao fberglaoo.

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Seeraj Team
A meetng wao organiied with one of the membero of the Seeraj team in order to obtain informaton
about the proceoo that the Seeraj team uoed to manufacture their caro. A oummary of the informaton
obtained in the meetng io in Appendix A.

The Seeraj team frot machined blue foam, uoing a CNC, to make the plug of the vehicle. A layer of
fberglaoo wao applied to the plug, and ouboequently a layer of epoxy and hardener wao added. Thio wao
repeated untl the deoired number of layero wao achieved, afer which it wao allowed to dry. Afer
becoming dry, the fberglaoo wao removed from the plug, and it then became the mold. Two layero of
prepreg carbon fber oandwiched by a honeycomb otructure were applied to the mold. Thio wao then
cured in an autoclave, producing the part.

Panther Rage Team

The manufacturing method uoed by the Panther Rage Team for their car, which io in the batery electric
category of the Shell Eco Marathon competton, wao obtained from their fnal report, found on the
internet [CITATION Qui11 \l 1033 ].

Fiberglaoo wao uoed for the conotructon of the body, and the windowo were made of acrylic. To make
the body, a plywood “okeleton” of the body wao manufactured, which wao flled with foam to create the
mold. Layero of fberglaoo along with polyeoter reoin were applied to thio mold and allowed to dry. The
car wao then painted.

They began the molding proceoo by frot making a CAD model of the body (Figure 6), from which the CAD
model of a okeleton wao created. The oectono of the okeleton CAD model (Figure 7) were printed to
ocale and were traced onto oectono of plywood, which were ouboequently cut into ohape. Theoe
oectono were ocrewed together to create the okeleton (Figure 8). Afer that, polyioocynurate foam, cut
by a box cuter, wao uoed to fll the gapo between the oectono, and then wao glued to the oectono uoing
gel contact cement. Thio wao lef to dry, and afer the drying proceoo, the gapo were flled with an
expandable foam opray. Finally, thio foam wao oanded to create the fnal mold.

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Figure 6c: This fgure shows the CAD model of the desired body to be manufacturede

Figure 7: This fgure shows the skeleton CAD model that will be used to make the molde

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Figure 8: This fgure shows the rlywood skeleton of the Team Panther car that was made to make the molde

Figure 9: This fgure shows the fnished molde Noote that the orange lines on the mold are the exrandable foam srraye

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Afer the mold wao created, the fberglaoo wao applied. The frameo of the windowo were oanded into the
window, and were not covered by the fberglaoo. Then, in order, a layer of polyeoter reoin-hardener
mixture, a layer of fberglaoo mat, and another layer of the mixture were applied to the mold ourface.
Thio wao lef to dry. Figure 10 ohowo fberglaoo being applied to the body, while Figure 11 ohowo the fnal
pre-painted dried body.

Figure 10: This fgure shows fberglass mat being arrlied to the molde

Figure 11: The above fgure shows a chassis contained within the dried bodye

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Material
The materialo uoed by the diferent teamo wao aloo reoearched. Unfortunately, not much informaton
wao found. The following table lioto the material informaton that wao found:

Vehicle Body Material Windows Source of Information

Material
Supermilaege 6oi Fiberglaoo Cloth Polycarbonat [ CITATION Ing09 \l 1033
Design Team 16 Epoxy and Hardener e ]
Car 3/8” Polyotyrene Foam Core 1/16” Thick
Hand Formed
A Car from Florida 4 Layero of Fiberglaoo Cloth Plexiglao [CITATION Aco12 \l 1033
International ]
University
Eco Veiculo’s XC20 Carbon fbre Polycarbonat [ CITATION Eco141 \l
Epoxy e 1033 ]
Chalmers Vera Single Layer of Carbon Fiber - [CITATION Cha14 \l 1033
Team’s Vera ]
Seeraj’s Wahj 2 Two Layero of Prepreg Carbon Fiber Polycarbonat [ CITATION Ber14 \l 1033
Epoxy and Hardener e ]
Honeycomb Sandwich
Panther Rage’s Car Fiberglaoo Cloth (Two Layero?) Acrylic [CITATION Qui11 \l 1033
Polyeoter Reoin and Hardener ]
Table 4: Thio table ohowo the materialo of choice that were found for oome teamo. Note that the
Supermileage Deoign Team 16 car might not have been manufactured.

Car Shape Design

Preliminary Car Specifcations and Drawing
The car wao modeled afer the caro from the other teamo. The car wao frot made to be 280 cm in length
and 60 cm in height, with two front wheelo being the oteering wheelo, and one rear driving wheel. The
body of the car will be made of two parto: an upper part and a lower part. Ao the width of the car
depended on whether the wheelo are inoide the body or not, which wao not decided yet, a preliminary
width wao not oelected for the car. A oide-view of the car wao frot oketched on paper (Figure 12), and
then wao made into a oof 2D oketch uoing SolidWorko™ (Figure 13). A 3D human model, with a height of
about 175 cm, wao inoerted into the 2D oketch in order to enoure that the driver hao enough opace in the
car. The human body model uoed wao made by [ CITATION Hru14 \l 1033 ].

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Figure 12: The rreliminary hand drawn sketches of the side view of the car are shown heree

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Figure 13: This fgure shows two similar rreliminary 2D sketches made for the car, along with a human body modele Noote that
all dimensions are in cme

Page 16 of 65
Updated Car Specifcations and 3D CAD Model
Conoultng with the chaooio team, it wao decided that the car will be 300 cm in length, 60 cm in height,
and 60 cm in width, and that the wheelo will be inoide the car. However, a problem arooe: the width of
the car wao not enough to make the minimum turning radiuo of the car the neceooary 6 m ao dictated by
the Shell Eco Marathon ruleo [ CITATION She \l 1033 ], which required the front wheelo to be able to
turn about 17° from the otraight pooiton, ao calculated by the chaooio team. To accommodate the
required turning of the wheel, the width of the car wao increaoed to about 72 cm, while all other
dimenoiono were kept the oame. The clearance of the car wao aloo ouboequently raioed to 10 cm. Note
that all the 3D modelo were made uoing SolidWorko™. The following fgureo (Figureo 14-16) ohow the
evoluton of the 3D model of the car.

Afer the 3D model wao fniohed, an aooembly conoiotng of the body ohello, the frame model provided by
the chaooio team, and treo wao made. The creaton of the 3D model took more tme than wao expected,
and thio wao mainly due to the many changeo that were made and are otll being made to the body and
chaooio deoigno.

Figure 14: The rreliminary 3D model of the body is shown heree

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Figure 15: A much smoother 3D model is shown in this fguree This model is 6c0 cm in width, which was subsequently changede

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Page 19 of 65
Figure 16c: The rrevious three fgures show the assembly of the car containing the major rarts: the body, the chassis frame, and
the trese

Figure 17: The share of the car was again smoothened out to imrrove the aerodynamics of the vehiclee

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Final Car Model
To improve the aerodynamico and the aeothetco of the car, and to ft the body to the updated chaooio
deoign from the chaooio team, the car wao fnally changed to the model ohown in Figure 19.
Furthermore, a virtual vioibility teot mimicking the teot carried out at the competton wao conducted in
order to enoure that the driver’o vioibility complieo with the ruleo. The vioibility teot at the Shell Eco-
Marathon involveo placing the car at a center of a circle, and 60 cm high column are placed 4 metero
away every 30°, otartng from the lef oide of the driver to the right oide of the driver, which completeo a
180° arc. Figure 18 ohowo the oet-up.

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Figure 18: These three fgures show the virtual visibility test that was conductede The fgures were made using SolidWorkse

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Figure 19: This fgure shows the fnal design of the care The tor rart of this design was manufacturede

Proposed Method of Assembly

One important aopect of manufacturing to conoider io the method of aooembly of the diferent parto
together. Although thio hao not been decided yet, methodo of aooembly had been propooed.

For ataching the lower body to the chaooio frame, a bolt can be inoerted into a hole drilled on both the
lower body and the chaooio frame, ao ohown in Figure 20. Ao recommended by [ CITATION Mai02 \l 1033

Page 23 of 65
], a metal inoert will be uoed in the hole of the lower body ao it will be a compooite material. Holeo,
however, create otreoo concentratono and fber diocontnuity in the compooite, and compooiteo might
aloo be hard to machine [ CITATION Mai02 \l 1033 ]. Thuo, to avoid drilling holeo in the compooite,
another method wao propooed, and that io to glue a bracket onto the body, drill a hole through the
bracket and through the chaooio, and then inoert a bolt into the hole, ao ohown in Figure 21.

Ao for ataching the upper body to the lower body, the Shell Eco Marathon ruleo require that the cockpit
“door” be eaoily opened from the outoide and without the uoe of toolo, and to be eaoily opened from
the inoide of the car within 10 oecondo [ CITATION She \l 1033 ]. To achieve thio, two methodo were
propooed. The frot method io to uoe Velcro™ tape at oome pointo on the upper edgeo of the two parto of
the body. The oecond method io to make either the lower body or the upper body olightly omaller, and
then the upper body will oimply reot on the lower body (Figure 22).

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Figure 20: This fgure shows the frst rrorosed method of joining the lower body to the chassis framee The image of the metal
insert was obtained from [ CITATIONo Yar14 \l 1033 ]e

Figure 21: This fgure shows the second rrorosed method of joining the lower body to the chassis framee

Page 25 of 65
 Figure 22: This fgure shows the second rrorosed method of joining the urrer body to the lower bodye In this case, the lower
body is slightly smaller than the urrer bodye

Finally, to join the windowo with the upper body, riveto will be uoed, ao ohown in Figure 20.

Figure 23: The rrorosed method joining the window to the urrer body is shown in this fguree The window in this case is made
of rolycarbonatee

Page 26 of 65
Material Selection
Materials Research
Before choooing a material of the body, oome reoearch wao done into the diferent typeo of compooiteo
and the properteo of compooiteo. The following informaton wao oummariied from [ CITATION Mai02 \l
1033 ].

Reinforcement
In a compooite material, the fber giveo the otrength and the otfneoo to the part, and it carrieo the load.
The compooite material io otrongeot along the axio of the fber. The fbero could be long or ohort,
contnuouo or diocontnuouo. Contnuouo fber compooiteo have much ouperior properteo than the
matrix, while ohort fbero generally give woroe properteo than their contnuouo fber counterparto. The
fber form to be oelected dependo on whether it will be uoed in a otructural, for which contnuouo or
long fbero are recommended, or a non-otructural, for which ohort fbero are recommended, product,
and on the opecifc manufacturing proceoo that will be uoed.

Another important conoideraton io the type of fabrico. There are mainly two typeo: woven and
noncrimp. Woven fabrico are common for marine wet lay-up applicatono. Woven fabrico are
inexpenoive, and they give the poooibility of having a combinaton of fber materialo in the fabrico, oay
carbon and glaoo. There are many weave paterno for a woven fabric, and thooe muot be oelected baoed
on the required orientaton of the fbero. Noncrimp fabrico, on the other hand, are made up of parallel
yarno ottched together with polyeoter thread. They generally ofer greater otrength than woven fabrico.

Matrix
The matrix in a compooite material giveo the rigidity and the environmental reoiotance to the part. The
failure mode of a part greatly dependo on the matrix material uoed and ito ouitability for the fber uoed.
To allow the fbero to carry the maximum poooible load, the matrix muot be a material with a lower
moduluo, and a higher elongaton, than the fber uoed. The matrix uoed aloo giveo the limito for the
acceptable oervice operatng temperatureo, and aloo defneo the proceoo variableo in manufacturing.

There are two main typeo of matrix materialo, and thooe are thermooeto, and thermoplaotco. The
properteo of each are outlined below:

Thermosets
 Might oofen at high temperatureo.
 Britle. Uoually uoed with fller and reinforcement.
 Ao the reoin io uoually liquid at room temperature, it io eaoier to proceoo than thermoplaotco.
 Thermooet reoino are more thermally otable, dimenoionally otable, and rigid, than thermoplaotco.
 Thermooet reoino give more electrical, chemical, and oolvent, reoiotance than thermoplaotco.

Thermoplastics
 Ofer greater ductlity and toughneoo than thermooeto.
 Can be reohaped.
 Thermoplaotco have poorer creep reoiotance than thermooeto, eopecially at high temperatureo.
 Require greater temperatureo and preooureo during proceooing.

Page 27 of 65
Prepregs
Preprego are fabrico that have been pre-impregnated with reoin. Preprego give uniform properteo,
uniform fber/reoin mix, and complete reoin impregnaton. Preprego give parto with higher fber volume
fracton than non-preprego, and give more controlled properteo, greater otrength and greater otfneoo.
Preprego eliminate the need to weigh and mix the reoin during the manufacturing proceoo, and thuo
tme io oaved. Preprego have oeveral dioadvantageo, however. They are more expenoive, and thermooet
preprego need to be refrigerated.

Material Selection Parameters

Looking over the oummary of the reoearch, it oeemo that to properly oelect a compooite material, the
following parametero would need to be decided:
 Fiber material(o)
 Matrix material (or reoin material)
 Fiber and reoin content
 Fiber form
 Type of fabric
 Weave patern (if woven fabrico are uoed)
 Prepreg or non-prepreg

Material Choice
The ruleo of the Shell Eco-Marathon [ CITATION She \l 1033 ] require that the body doeo not deform
under the efect of wind. Thio wao tranolated to mean that the body material will need to be otf enough
to have minimal de ecton. Referring to both the reoearch and the benchmarking, it oeemo that the beot
material to choooe would be carbon fber impregnated with epoxy reoin, or fberglaoo impregnated with
either polyeoter or epoxy reoin. Due to the difculty of obtaining carbon fber, and the high coot of
carbon fber, fberglaoo wao oelected to be the reinforcement, although thio might be changed later on.
The reoin uoed would either be epoxy reoin or polyeoter reoin. Due to the inexperience of the team
membero in the feld of compooite deoign, the fnal material hao not been oelected yet. A method of
oelectng the appropriate material hao been propooed, however, and that io to frot otart with two layero
of fberglaoo, which io about the average of what the other teamo uoe, and then increaoe or decreaoe
depending on the reoulto obtained. A oample of the material could be obtained from a oupplier and
teoted to oee if it io enough for the purpooe of the project.

Page 28 of 65
Supplier
In order to avoid the ohipping cooto and the ohipping tme, local companieo dealing with fberglaoo in
Saudi Arabia were approached. The following io a oummary of the oupplier and oome of the producto
provided, along with priceo:

Name: AlKhaeej AlArabi FiberGlaoo Factory

Location: AlKhobar'o Induotrial City

Catalogue (Arranged ao Product Name, Amount, Price):

 Fiberglaoo Chopped 300 (g/m2), 127 cm x 2500 cm Roll, 500 SR
 Fiberglaoo Woven 600 or 800 (g/m 2), 127cm x 1200 cm Roll, 500 SR
 Reoin, 1 kg, 20 SR
 Releaoe, 1 box (unknown oiie), 50 SR
 Hardener, 1 kg, 60 SR
 Gel Coat, 5 kg, 600 SR
 Acrylic, 1.2x2.4m, 1 oheet, 600 SR

Page 29 of 65
Manufacturing Research
Manufacturing Methods
The following two methodo were reoearched ao they were deemed to be feaoible to uoe, in termo of the
equipment required. The following informaton wao obtained from [ CITATION Mai02 \l 1033 ]. Note
that the prepreg lay-up proceoo wao the proceoo uoed by the Seeraj Team to manufacture the Wahj 2
body, while the wet lay-up proceoo wao uoed by the Seeraj Team to manufacture the fberglaoo mold for
the Wahj 2 body, and by the Panther Rage Team to manufacture the body of their car.

The actual method to be uoed for the manufacturing of the project dependo on the material choice, the
available equipment, and the deoired quality of the body.

Prepreg Lay-Up
Material
Carbon/epoxy preprego are mootly uoed for thio proceoo. Glaoo/epoxy and Kevlar/epoxy are much leoo
uoed than Carbon/epoxy preprego. Uoually, unidirectonal fber preprego are uoed.

Tooling
 Open mold.
 For prototypeo, machined metalo, woodo, or plaotco are uoed ao toolo.
 For aeroopace componento, tooling io uoually of a compooite material, ouch ao carbon/epoxy prepreg,
glaoo/epoxy prepreg, etc.

Manufacturing Steps
1. The prepreg material io taken out of the refrigerator and allowed to thaw, in ito original packaging, at
room temperature.
2. When the prepreg reacheo room temperature, it io made into the required dimenoiono by cutng. The
prepreg io put on a cutng board, and then cut uoing a oteel ruler and a utlity knife.
3. The mold io cleaned.
4. The ourface of the mold io covered with releaoe agent. Thio allowo the part to be eaoily removable from
the mold afer fabricaton.
5. The prepreg io put on the mold, removing the backing flm frot.
6. Afer each layer of prepreg io applied, entrapped air io removed via a oqueeiing roller.
7. The next otep io vacuum bagging the part. The following layero are put on top of the prepreg in oequence:
a. a releaoe flm (a perforated flm through which air, exceoo reoin, or volatleo can leak),
b. a bleeder (a porouo fabric that aboorbo moioture and exceoo reoin),
c. a barrier flm,
d. a breather layer (a breather createo even preooure around the part, and io porouo oo that air and
volatleo can eocape),
e. and fnally a vacuum bag.
8. The vacuum bag io oealed on all oideo by uoing a oealant tape. The entre mold, if it io porouo, could be
contained in the vacuum bag.
9. A vacuum io created inoide the vacuum bag by inoertng a vacuum hooe and noiile.
10. The mold io now put inoide an autoclave for curing. Both the reoin type and the dimenoiono of the part
afect the cure cycle.
11. Afer the part io cured and it coolo down, the part io taken out.

Page 30 of 65
Advantages
 Giveo high fber volume fracton, ao preprego generally have at leaot 60% fber volume fracton.
 High otrength and high otfneoo parto can be made.

Disadvantages
 It io cootly.

Wet Lay-Up
Material
E-glaoo io the moot common reinforcing material uoed in the commercial oector, but glaoo, Kevlar and
carbon fber woven fabrico are aloo generally uoed. Reoino uoed include epoxy, polyeoter, and vinyleoter,
with polyeoter being the moot widely uoed for boat building and other commercial producto.

Tooling
 For prototypeo, oteel, wood, glaoo fber, and other materialo, are uoed.
 FRP moldo are uoed in the boatng induotry to manufacture yacht hullo.

Manufacturing Steps
1. The ourface of the mold io covered with a releaoe agent.
2. A gel coat io applied to improve the ourface fniohed. It io allowed to gel.
3. There are two wayo to apply the fabric. The fabric could be frot put on the mold, and then weted with
reoin, or the fabric could be weted frot, and then put on the mold.
4. A oqueeiing roller io uoed to opread the reoin evenly over the fabric.
5. If neceooary, more layero of weted fabrico are applied.
6. The part io lef at room temperature to cure.

Advantages
 Any combinaton of fber/fber orientaton/reoin could be uoed.
 Liquid reoin, mat, and fabric material, the raw materialo for thio proceoo, are leoo cootly than preprego.

Disadvantages
 High fber volume fracton parto cannot be made.

Page 31 of 65
Cost Estimation
Material Cost
Note that to eotmate the coot of the material to be uoed for the body, oeveral aooumptono were made.
Firot, the ourface area of the car wao obtained via SolidWorko™ to be equal to about 5.5 m 2 for the
preliminary 3D model. The length of the roll required for one layer of fabric wao eotmated to be about 8
metero, which io twice the length of the car pluo two metero. Thio io an overly conoervatve fgure. For
the 3K, Plain Weave Carbon Fiber fabric from [ CITATION Fib14 \l 1033 ], for example, the width of the
roll io 1.27 metero, while the width aooumed for the car wao 0.6 m.

The weight of each layer of material wao eotmated through ito ourface area (the area for the windowo
wao not taken into account), while the coot wao eotmated by the length of roll needed. The reoin
content wao calculated ao 1.745 tmeo the fber weight, according to what io done by the [CITATION
Fib141 \l 1033 ] Materialo Calculator (Note that the Materialo Calculator actually uoeo 1.75 inotead of
1.745). The weight of the hardener wao aloo calculated according to the amounto recommended by
[ CITATION Fib14 \l 1033 ], but only to eotmate ito coot; ito weight wao not added to the total weight.
Thio might be a wrong aooumpton, however. Thuo, the total weight indicated in the following tableo
includeo the weight, per layer of fabric, of the fabric and the reoin, while the total coot includeo the coot,
per layer of fabric, of the fabric, the reoin, and the hardener. Note that the coot doeo not include
ohipping coot.

Material Thickness (in) Weight/Layer (kg) Cost/

Layer
Carbon Fibers with Epoxy Resin
3K, Plain Weave 0.012 2.92 $451.82
1K, Plain Weave Ultralight 0.009 1.79 $1,522.83
3K, 2X2 Twill Weave 0.012 2.92 $451.82
Prepreg 3K, 2X2 Twill Weave 0.012 <2.92 $1,038.93
6K, 5HS Weave 0.024 5.58 $680.22
Fiberglass with Polyester Resin
Style 120 E-Glass 0.0046 1.6 $116.50
Style 7781 E-Glass 0.0089 4.46 $126.52
Style 6781 S2-Glass 0.0097 4.53 $257.61
STYLE 3733, 6 Oz Fabric 0.007 3.07 $86.08
Table 5: Thio table lioto the weight per layer and the coot per layer for diferent material combinatono.
The material coot and properteo were obtained from [ CITATION Fib14 \l 1033 ].

Other Costs
The Shell Eco-Marathon require oeveral parto to be added to the oyotem, and theoe include driver oafety
gear, horn, and otarter light, to name a few [ CITATION She \l 1033 ]. Theoe parto were oearched for on
the internet and their priceo were obtained. Note that many of theoe parto might actually be bought in
Saudi Arabia inotead of being ordered, ao that would probably be cheaper and more convenient. The liot
of the parto along with the priceo are ohown in the following table (Table 6).

Page 32 of 65
Part Model Name Picture Cost Website
Seat Belt RCI Platnum Serieo $69.97 htp://
Racing Harneooeo www.oummitrac
9210PL ing.com/int/
parto/rci-
9210pl/
overview/

Race Overalls Sparco Driver Single $150 htp://

Layer Driving Suit www.oaferacer.c
om/oparco-
driver-oingle-
layer-driving-ouit

Helmet G-Force Z2 Graphico $79.99 htp://

Motorcycle Helmet www.oaferacer.c
om/g-force-i2-
graphico-
motorcycle-
helmet

Gloves G-Force Gfcrew Gloveo $14.99 htp://

www.oaferacer.c
om/g-force-
gfcrew-gloveo

Horn HORN - KW9 High- 11.00 € htp://

pitched - 12V tax excl. www.eohopoem.
com/

Page 33 of 65
Horn Installation Trigger Horno $49.99 htp://
Kit Inotallaton Relay & each. www.autoanythi
Harneoo Kit ng.com/car-
horno/
74A6366A0A0.a
opx

Speedometer Sigma BC 1009 Bicycle $29.99 htp://

Speedometer www.amaion.co
m/Sigma-BC-
1009-Bicycle-
Speedometer/
dp/
B003BCG9EK/
ref=ig_bo_5393
951011_4
Starter Light 4x Red Large Bulb 1156 $9.95 htp://
BA15S 15mm Bayonet www.ebay.com/
Baoe Lamp 12v 21W itm/4x-Red-
Turn Signal Light Large-Bulb-
1156-BA15S-
15mm-Bayonet-
Baoe-Lamp-12v-
21W-Turn-
Signal-Light-/
400646672551
Fire Extinguisher 1kg ABC Type Fire £11.70 htp://
Extnguioher - BS EN3 www.amaion.co
.uk/1kg-ABC-
Type-Fire-
Extnguioher/dp/
B0055QOHMQ

Table 6: Thio table ohowo a liot of the parto required by the Shell Eco-Marathon Ruleo.

Page 34 of 65
Aerodynamics Analysis of the Car Body
Summary of Results
Uoing CFD through the oofware ANSYS Fluent, the coefcient of drag wao calculated for a olightly earlier
veroion of the fnal car (Figure 25) to be about 0.115 at an air opeed of 45 km/h. In comparioon, the
Remmi 7 car, which achieved a record diotance of 3306 km with one liter of fuel, had a coefcient of
drag of 0.0871 at 45 km/h. Thuo, ao the ohape of the car wao oimilar to the Remmi 7 car, thio oeemo to
give confdence to the reoulto obtained.

Finite Element Model

In the CFD analyoio, the vehicle wao placed in a large virtual wind tunnel “box”. Air owo in from the far
end of the box at a opeed of 45 km/h, while the other end of the box wao aooumed to be the preooure
outlet (Figure 24). The other ourfaceo of the virtual wind tunnel box had a oymmetric boundary conditon
applied to them. The no-olip conditon wao applied to the road and the external ourfaceo of the car. The
viocouo model uoed wao the realiiable k-epoilon viocouo model with non-equilibrium wall functono wao
uoed. Tetrahedral elemento were uoed throughout the model, with the excepton that priomatc
elemento were uoed near the ourface of the “road” and the ourfaceo of the car. Thio, according to
[ CITATION Lan05 \l 1033 ], would provide more accurate reoulto in the caoe of external vehicle
aerodynamico. A omall box around the vehicle wao meohed very fnely, while areao away from thio box
gradually increaoed in oiie. Thio wao done to achieve a balance between the computng tme required
and the accuracy of the reoulto.

Unfortunately, the original ANSYS Fluent data fleo appear to have been corrupted. It wao deoired to
reproduce a fgure of the meoh, ohowing the boundary conditono. Figure 24 ohowo a oimplifed view of
the virtual wind tunnel uoed in the analyoio, along with the applied boundary conditono.

The YouTube video tutorial oerieo on the analyoio of the external vehicle aerodynamico uoing ANSYS
Fluent by “ocipy” were heavily referred to. Furthermore, [ CITATION Lan05 \l 1033 ] wao referred to for
guidelineo on creatng a high quality meoh. The contouro of preooure coefcient are ohown in Figure 26,
while Figure 27 ohowo the contour of velocity magnitude.

Page 35 of 65
 Box extendo at
Velocity leaot three car Preooure
Inlet lengtho into the Outlet
“page” At leaot three
car lengtho

At leaot three
car lengtho At leaot fve car
lengtho

Car box

Figure 24: This fgure shows a simrliied view of the virtual wind tunnel, and the arrlied boundary conditonse The urrer, lower,
right, and lef surfaces of the wind tunnel box have a symmetric boundary conditone The rectangle labeled “Car box” was a locally
refned area in the meshe

Figure 25: This was the second-last design of the share of the care This was the design that was analyzed for aerodynamic
rerformancee This share achieved a coefcient of drag of about 0e115e

Page 36 of 65
Page 37 of 65
Page 38 of 65
 Figure 26c: The rressure coefcient contours as obtained from the CFD analysis are shown in these fgurese

Figure 27: The contour of velocity magnitude is shown in this fguree Noote that the inlet air sreed is 12e5 m/se

Page 39 of 65
Paper Prototype
To get a oenoe of the approximate ohape and oiie of the car, a paper prototype of the car wao
manufactured. Firot, about fve diferent crooo-oectono along the length of the car, and one oecton at
half of the height the car, were printed to ocale. Then, the paper wao placed on the cardboard, and the
pieceo were cut. The pieceo were then atached uoing glue, and a black bag wao placed on top to give a
rough idea of the curvature of the car ourfaceo. Figureo 29-33 ohow the manufacturing proceoo of the
paper prototype. Note that the paper prototype wao done for an early veroion of the body, which hao
been reproduced in Figure 27 for convenience.

Figure 28: This fgure shows the body version that used to make the rarer rrototyree

Page 40 of 65
 Figure 29: This fgure shows an actual-size scale of one of the cross-sectons along the length of the bodye

Figure 30: Lef: Cross-sectons to be glued on the middle body cross-sectone Right: The middle cross-secton of the bodye

Page 41 of 65
Figure 31: This fgure shows the comrleted rarer rrototyre before it was covered with the black rlastc bage

Figure 32: This fgure shows the fnished rarer rrototyree

Page 42 of 65
Figure 33: This is a front view of the comrleted rarer rrototyree

Page 43 of 65
Working Prototype
The oecond phaoe of manufacturing io the working prototype. The goal of thio prototype io to
manufacture, with the help of the chaooio and engine groupo, a complete car that io fully functonal, in
order to gain experience in manufacturing. It wao decided that the body for the prototype will be made
of two layero of chopped fberglaoo mat, with polyeoter reoin. Thio material wao chooen ao many other
teamo have had uoed a oimilar choice, and becauoe of the availability of material and ito low coot. The
manufacturing of the fberglaoo parto wao made through two major otageo: mold manufacturing, and
then fberglaoo laying. Note that, due to the ohortage of tme, only the upper part of the body wao made.
The upper body wao divided into a front and back part, for two main reaoono. The frot reaoon io to gain
experience by manufacturing a part of the upper body rather than the whole part, and ao the upper part
needo to be quickly removable by the driver or an outoide peroon, having only the front part be
removable wao aooumed to be eaoier and faoter.

Manufacturing Testing
Before the fberglaoo wao laid, oeveral teoto were conducted on teot pieceo in order to determine a
ouitable releaoe agent. The foam uoed wao polyotyrene foam, which io eaoily damaged by polyeoter reoin.
Ao thio type of reoin wao uoed, a method of protectng the foam needed to be found. Furthermore, the
appropriate number of layero needed to be determined. Afer oeveral teot trialo and reoearch, the team
fnally decided to take theoe otepo: cover the foam mold with puty, apply honey wax releaoe onto the
puty, and then apply hairopray. Figure 34 ohowo an example teot oample. The appropriate number of
layero wao deemed to be two to three layero of chopped fberglaoo mat.

Figure 34: This fgure shows an examrle test samrlee In

this trial, the foam was covered in rlastc, and then
fberglass was laide As can be seen, the resin had
renetrated the rlastc and greatly corroded the foame

Engine Cover Part

Mold Manufacturing
The manufacturing of the mold involved
three major otepo: cutng and aooembling
foam crooo-oectono along the length of the
car body, covering the foam with puty, and
then laying the fberglaoo. One important
note io that, unlike uoual practce, no fberglaoo mold wao made. The fnal fberglaoo part wao directly
made from the foam mold. Thio giveo the outer ourface of the part a rough ourface, which would need to
be oanded or otherwioe fxed, in order to not adveroely afect the aerodynamico of the car body. Figureo
35-41 ohow the manufacturing proceoo of the mold.

Page 44 of 65
Figure 35: This fgure shows a foam board loaded into the CNoC machine at FABLAB Dhahrane

Figure 36c: Some of the cross-sectons that were cut are shown heree

Page 45 of 65
Figure 37: This fgure shows the foam rieces for the back rart of the urrer body being assemblede

Figure 38: This is a ricture of the assembled foam riecese Two rods were used in order to rrevent rotaton of the riecese

Page 46 of 65
Figure 39: This fgure shows the assembled foam rieces afer being sandede The sanding rrocess is close to being fnished at this
rointe

Figure 40: This fgure shows the assembled foam rieces afer a layer of wall ruty was arrliede A total of three layers were
arrliede The mold is sanded afer each layer is arrliede

Page 47 of 65
Figure 41: This fgure shows the mold being raintede The raint was arrlied to give a beter surface fnish to the rroduct, which
was realized to be an erroneous assumrton later one A total of two layers were arrlied to the back urrer rart (engine cover)e

Laying the Fiberglass

The foam that wao uoed io polyotyrene foam, which eaoily geto damaged by the polyeoter reoin intended
to be uoed. Thuo, to protect the foam, and to allow eaoy releaoe of the part from the mold, about oix
layero of honey wax mold releaoe wao applied to the mold, following by a thin layer of hair opray, which
provideo a protectve coatng. Then, the fberglaoo wao laid to produce the fnal part. Figureo 42-46 ohow
the otageo of laying the fberglaoo.

Figure 42: This fgure shows a layer of honey wax being arrlied to the bodye

Page 48 of 65
Figure 43: This fgure shows the mold being srrayed with hair srraye

Figure 44: This fgure shows the fberglass cut into rieces to allow for easy layinge

Page 49 of 65
 Figure 45: This fgure shows the fnal untrimmed fberglass rarte

Figure 46c: This fgure shows the mold from which the fberglass rart was madee The mold was slightly damaged on the rear side,
but it was mostly intacte

Page 50 of 65
Driver Cover Part
The manufacturing proceoo of the driver cover wao identcal to the manufacturing proceoo of the engine
cover, with the excepton that no paint wao applied thio tme. Ao wao mentoned earlier, wall paint wao
erroneouoly uoed to improve the ourface fnioh of the mold, when, in fact, it woroened it. Figureo 47-51
outline the manufacturing proceoo of the driver cover fberglaoo part.

Figure 47: This fgure shows the foam mold of the driver cover assembled and sandede

Figure 48: A layer of ruty was arrlied to the driver cover foam molde A total of three layers of ruty were arrliede

Page 51 of 65
Figure 49: Ceramic clay was used to outline the windows, in order to rrevent the fow of resin into the window regionse A layer
of honey wax release is being arrlied in rreraraton of laying the fberglasse

Figure 50: Fiberglass is being laid on the molde

Page 52 of 65
Figure 51: Probably due to erroneous arrlicaton of the honey wax mold release agent, the resin renetrated the ruty into the
foam molde This greatly damaged the foam mold as can be seen in this fguree (Comrare to Figure 45)

Assembly onto the Chassis

To atach the body parto onto the chaooio, pieceo of Plexiglao™ and aluminum oheet metal were uoed to
manufacture a non-permanent atachment ocheme. Velcro™ wao intended to be uoed to aid in
ataching. Figure 50 ohowo the trimmed driver cover part, while fgureo 52-60 ohow the atachment
ochemeo and the aooembled body. Note that the manufacturing of the atachment ochemeo have not
been fully completed yet, and it might be changed it in the future to a more reliable ocheme.

Page 53 of 65
Page 54 of 65
 Figure 52: This fgure shows the trimmed driver covere Noote that this rart will be rainted or covered with stckers, and acrylic
glass will be atached as the windowse

Figure 53: This fgure shows the chassis with the rreliminary atachment scheme atachede

Figure 54: This fgure shows the driver cover rlaced on the chassise

Page 55 of 65
Figure 55: The car being tested for sracee There seems to be enough srace for the drivere

Figure 56c: The driver's front visibility is being testede

Page 56 of 65
 Figure 57: The urrer body rlaced on the chassise Driver srace seems to be adequate, but there seems not to be enough srace
for the full rotaton of the trese Noote that, however, the front wheels need only to be able to rotate about 17° on either side of
the treee

Page 57 of 65
Figure 58: These fgure shows the rreliminary atachment scheme of the urrer body rarts to the roll-bare

Page 58 of 65
Figure 59: These fgures show the atachment scheme at the front of the driver covere Noote that not all the rarts have been
assembled yete

Page 59 of 65
Figure 6c0: This fgure shows the rreliminary atachment scheme at the rear of the engine covere Noote that this has not been fully
assembled yete

Remaining Tasks to Be Done

Due to the ohortage of tme, there are many taoko remaining to be fniohed. The following liot giveo a
roughly chronological order of the expected remaining taoko:

 A ouitable atachment ocheme to aooemble the upper body to the chaooio muot be deoigned and
manufactured.
 The upper body parto need to be painted, or otckero applied, and the windowo need to be
made.
 The lower part of the body needo to be manufactured.
 The fnal prototype needo to be manufactured.

Conclusion
Unfortunately, the project wao not fniohed in the intended tmeframe, and thio io mainly due to the
unexpectedly tme duraton of many of the taoko that were planned. However, much wao learned during
thio project. Much wao learned about the deoign proceoo of a real producto, the need for accurate
drawingo to allow for eaoy aooembly, and inter-group communicaton okillo. The otudento undertaking
thio project were introduced to the faocinatng world of compooiteo, and gained experience in deoigning
and manufacturing a compooite part. Experience in market reoearch wao aloo gained, during, for
inotance, the benchmarking phaoe of the deoign.

Page 60 of 65
Appendix A – Summary of Meeting with Mr. Berrimi of
Seeraj [ CITATION Ber14 \l 10 3 3 ]
Old CNC Machine Details:

The machine io not working. It might be fxable though.

Seeraj Team io no longer uoing it.

Dimensions: 6mx3m

New CNC Machine Details:

Currently on order. No arrival date known.

Seeraj Team io going to otart manufacturing in Term 141.

We might be able to uoe it. We need to contact Abu Sharifa for more detailo.

Manufacturing Process:

1) Blue foam wao machined with a CNC machine to the deoired ohape.

2) Fiber glaoo wao applied to the ourface of the blue foam, along with epoxy and a hardener material.
Thio wao cured in an oven.

3) The fber glaoo wao removed from the blue foam. Thio fber glaoo io the mold.

4) Prepreg carbon fber wao applied ao followo:

1) A layer of carbon fber wao applied.

2) A layer of honeycomb wao applied for otfneoo.

3) A oecond layer of carbon fber wao applied.

4) If there are any bendo or lapo, oome carbon fber io placed on top of theoe defecto to improve
otrength.

Time Required: About 2 weeko for manufacturing, 3 weeko for materialo arrival. The Seerja Body Group
hao 5 membero, while 3 membero worked full tme on the manufacturing. The canopy wao made in
about 10 houro by one member. It takeo about 18 houro for one part to be manufactured.

Cost: 300,000 Riyalo wao the total manufacturing coot, including manufacturing the CNC machine.
Eotmated coot for juot the manufacturing io about 50,000 riyalo.

Programming: To uoe the CNC machine, oomeone will have to learn how to program it. There io an
inotructor coming along with the new CNC machine to teach a couroe in programming that machine. We
might be able to atend that couroe. We need to aok Abu Sharifa for more detailo.

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Other: They made the body in two parto, the canopy and the botom part. Several Aluminum jointo were
riveted and epoxied into the lower body. Spring ocrewo were uoed to atach the canopy to the botom
part.

Works Cited
Acoota, Bryand, Marco Betancourt and Fernando Pinheiro. "Shell Eco-Marathon." Senior Deoign Project
Final Report. Florida Internatonal Unveroity, 2012. Web. <htp://www.mme.fu.edu/wp-
content/uploado/2013/04/R-T1-ShellEcoMarathon.pdf>.

Berrimi, Chihab. Interview. Mohamed Laradji. 16 March 2014.

Chalmero Vera Team. n.d. 4 May 2014. <htp://chalmeroverateam.oe/>.

Eco Veículo A. I. D. T. n.d. Web. 4 May 2014. <htp://www.ecoveiculo.com/>.

Fibre Glaot Developmento Corporaton. Fibre Glast 2014 Catalog. Fibre Glaot, 2014. Web.

—. "Materialo Calculator." n.d. Fibre Glaste Web. 4 May 2014.

<htp://www.fbreglaot.com/fbreglaot_materialo_calculator>.

Hrubec, Tomáš. "IKEA-Boy." SolidWorks Bibliothek - Mensch-Modelle. n.d. Web. 4 May 2014.
<htp://oolidworko.cad.de/lib_menoch01.htm>.

Inglio, Peter, Scot Flindall and Jaoon Belliveau. "2009/2010 Supermileage Car: Chaooio & Shell." MECH
4010 December Report. Dalhouoie Univeroity, 2009. Web.

Lanfrit, Marco. Best Practce Guidelines for Handling Automotve External Aerodynamics with FLUENoT.
Fluent Deutochland GmbH, 2005. Document.

Maiumdar, Sanjay. Comrosites Manufacturing: Materials, Product, and Process Engineering. CRC Preoo,
2002. Print.

Proto Inoa Club. n.d. Web. 4 May 2014. <htp://pic.inoa-lyon.fr/>.

Quiceno, Bryan, Pablo Salamea and Ryan Sampath. "Shell Eco-Marathon Competton: Final Report."
Senior Deoign Project Final Report. Florida Internatonal Univeroity, 2011. Web.
<htp://www.eng.fu.edu/mme/robotco/EML4905SeniorDeoignProject/SampleSeniorDeoignProj
ecto/2011Spring/2011opr-T10-PantherRage-Shell-Eco-Marathon-E-Car-FinalReport.pdf>.

Remmi Team. n.d. Web. 4 May 2014. <htp://remmi-team.com/content/vehicleo/>.

Shell. "Shell Eco-Marathon Ofcial Ruleo 2014: Chapter 1." Rulebook. n.d. Web.

UMH Team. n.d. 4 May 2014. <htp://umhteam.eo.tl/>.

Wanberg, John. Comrosite Materials Fabricaton Handbook #2: Comrosite Garage Series. Wolfgang
Publicatono, 2010. Print.

Yardley Productono Corporaton. Yardley® Mult-Sert™ Inserts. n.d. Web. 4 May 2014.
<htp://www.yardleyproducto.com/mult-oert>.

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