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Designing for the Illinois High Mileage Vehicle Competition
Keywords:
#Modeling #CIM #Manufacturing #Machining
As part of a semester-long project in my Computer-Integrated Manufacturing (CIM) course, I led a team in designing and constructing a high-mileage vehicle. The objective was to create a fuel efficient vehicle (we’re talking grams per mile) while staying within strict engineering and competition constraints. This experience was not only a technical challenge but a comprehensive exercise in design thinking, fabrication, and teamwork.
Technical Focus
I felt that my role was to guide the project from concept to execution. Our primary goal was to build a vehicle that could travel the greatest distance using the least amount of fuel, a design philosophy grounded in aerodynamics. We started with simulation-based designs, using computer-aided physics to optimize the aerodynamics of our model. Once we finalized the virtual renderings in Autodesk Inventor, we transitioned into fabrication.
I became proficient in several hands-on techniques including welding, plasma cutting, laser cutting, and CNC machining. These skills allowed us to bring our digital model into reality by constructing a metal chassis and assembling components like the braking system, drivetrain, and custom wraps. This project demanded not just technical ability, but constant iteration and communication across team members to ensure every component was aligned with the competition's engineering requirements.
From Concept to Competition
The construction process was broken into phases: initial design and simulation, scale modeling with PVC to test form factor compliance, full-scale fabrication using industrial tools, and final assembly with components like wheels, brakes, and the engine. Each phase required a new set of problem-solving skills, from navigating tight tolerances with CNC machines to ensuring structural integrity during welding.
Our efforts culminated in competing at the Illinois High Mileage Vehicle competition. While our vehicle used only a few grams of oil to complete a two-mile track, where we excelled was in brake construction as we placed second overall in the brake test category. This project was an amazing experience, blending classroom theory with real-world application, and giving me a strong foundation in mechanical design, precision fabrication, and leadership.
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