BAJA SAE

Project Spotlight: Engineering a Lightweight Differential Gearbox for Off-Road Excellence

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I embarked on the journey to design and fabricate a 305cc, 4-stroke, 10 bhp off-road car, culminating in the development of a custom differential gearbox. This project not only showcased my expertise in mechanical component design and 3D modeling but also my ability to innovate within the competitive automotive engineering landscape.

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Innovating for Performance

The core of this project was the design of a differential gearbox tailored for high-stress automotive applications. Utilizing the advanced features of Solidworks and Fusion 360, I meticulously created the gears, shafts, and the outer casing, ensuring each component was optimized for weight, durability, and performance.

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Achievements in Design and Functionality

• Weight Optimization: Through careful design and material selection, I successfully reduced the weight of the differential gearbox by 11% compared to other market options. This significant achievement not only enhances the vehicle's efficiency but also improves its agility and performance in off-road conditions.

• Solidworks Assembly: The integration of all designed parts into a cohesive differential gearbox system was completed using Solidworks Assembly. This process was critical in ensuring that the gearbox operated seamlessly, providing optimal functionality even in the most demanding situations.

• Competitive Recognition: My project was rigorously tested and evaluated in the Baja SAE 2018 competition, where it secured the 8th place in the static design event. Competing against 78 other teams, this achievement highlighted the strength and competitiveness of my design, marking a significant milestone in my engineering journey.

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Project Impact

This project stands as a testament to the power of individual innovation and the pursuit of engineering excellence. By combining technical skills with a creative approach to problem-solving, I was able to overcome design challenges and contribute meaningful advancements to the field of automotive engineering. The recognition received at the Baja SAE competition further validates the project's success and my commitment to pushing the boundaries of what's possible.

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Beyond the Gearbox

The success of this project has fueled my passion for automotive engineering and design. It serves as a foundation for future projects, inspiring continued innovation and exploration in the design and optimization of mechanical systems for performance vehicles.