FSAE Suspension Tabs & Welding Fixtures

This project focused on the suspension hardpoint tabs that connect the suspension system to the Longhorn Racing Electric chassis. These tabs are small parts, but they carry critical loads and directly affect suspension geometry, frame manufacturability, and vehicle setup accuracy.

The suspension hardpoints needed to survive worst-case loading while being accurately positioned during welding. Even small tab location errors can affect suspension geometry, alignment, and vehicle handling, so the goal was to design tabs and fixtures that were strong, manufacturable, and repeatable during frame assembly.

I designed suspension tabs for the front and rear hardpoints, created welding fixtures to hold the tabs during fabrication, and validated the hardpoint regions using ANSYS Mechanical. The fixture system was designed around maintaining accurate tab placement while still being practical for welding access and shop assembly.

I validated the suspension hardpoints under 6 kN load cases and kept peak von Mises stress below 240 MPa in the ANSYS FEA model. I designed and fabricated welding fixtures for 4 front and 5 rear suspension tabs per side, targeting ±0.015 in positional accuracy during frame assembly. I also balanced tab geometry, weld access, fixture clearance, and manufacturability while coordinating with suspension packaging constraints.

The final tab and fixture workflow supported stronger suspension mounting, cleaner fabrication setup, and more repeatable frame assembly. The FEA process helped verify that the hardpoints could handle expected loading, while the fixtures helped translate the CAD design into a more accurate physical chassis.

Continue refining fixture design and tab placement workflows for the next chassis cycle, improve manufacturability based on shop feedback, and use measured fabrication results to tighten future design and assembly assumptions.