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ORION COMPOSITES TEAM

Application of composite materials in the
production of a formula styled race car.



Impact Attenuator
Steering wheel
Bodyworks
Muffler
A-Arms
Pedals
Seat
Diffuser

Parts list
IMPACT ATTENUATOR
An impact attenuator is a structure used to decelerate
impacting vehicles gradually to a stop
By gradually decelerating the race-car, the frame and driver
are protected from significant deformation and injury.
The bulk of impact energy is transferred into the deformation
of the impact attenuator structure.
FSAE specifies that each car in operation must have an
attenuator that meets specifications and testing criteria.
MAJOR RULES
Minimum Dimensions: 200x100x200mm

Minimum energy to be absorbed: 7350J

Peak and average deceleration values: 40g and
20g respectively

Maximum deflection of anti-intrusion plate:
25.4mm
1.Pre-preg carbon fiber and epoxy foam

2.Trapezoidal structure
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Acceleration vs Disp
Acceleratio
STEERING WHEEL
Major design Consideration is DRIVER ERGONOMICS
Using of PU composites for
even higher strength as
compared to normal
composites
To be used for core of steering
wheel

Future plans
Steering wheel of hollow CF
pipe

BODYWORKS
Usage of quick release fasteners for fast assembly and disassembly
MUFFLER
Manufactured with the Air Intake and
Exhaust System

Weight Reduction of 1.5kgs

Glass wool for thermal and sound
insulation

FILAMENT WOUND glass fibre tube
Withstand 185 degree Celsius

A-Arms,Tie Rods,Push/Pull rods
Currently made from Mild Steel
Roll Wrapped Carbon Fiber Tubes
Mainly subjected to axial loads
Maximum tensile load achieved
19.36kN with .15mm thickness of
glue(LOCTITE 9466)
Total Weight reduction of about 3kgs
PEDALS
Acceleration, Clutch pedals OF DOW PU
foam
SEAT
Major design Consideration is DRIVER
ERGONOMICS
To house battery , fuel tank and other
electronic components in the cockpit
Sandwich structure to be used
Faces from Carbon Fiber
Core from ROHACELL IG FOAM
DIFFUSER
Analysis done on flow
simulation Solidworks

Down force achieved 10kgs

MANUFACTURING

Release Agent Testing
Improved Lay-Up Methodology
Vacuum infusion

RELEASE AGENT TESTING
General method of manufacturing
Mold elimination
Issue with this novel idea
Solution: Silicon based release agents
Testing: Done twice with and without
release agent, using differing concentrations
Future scope
IMPROVED LAY-UP METHODOLOGY
Art of wet lay-up
However, further improvements are required
Wet lay-up process
Application of wax
Usage of gel coat(Still in process)
Usage of roller to remove excess resin
PVA usage improvements
VACUUM INFUSION
Testing the vacuum infusion method for manufacturing
bodyworks, seat, floor

THANK YOU

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