V1 side view
The primary goal of our final project was to design and construct a roll cage for an off-road vehicle as outlined by the 2025 SAE Baja competition. Our objective was to develop a lightweight yet durable frame that could withstand significant obstacles over prolonged use while adhering strictly to safety standards.
Our team began by leveraging our individual strengths: I focused on the CAD design and physical assembly—areas where I excel due to my previous project experience—while my partner, who is more proficient in computational analysis, took on the dynamic testing using the FEA program ANSYS. This allowed us to efficiently identify stress concentration points and adjust our designs accordingly.
Throughout the project, communication was key. We exchanged numerous
V1 front left view
emails to discuss necessary modifications and tackled any arising issues promptly. Our collaboration was crucial in adapting our design to meet the rigorous demands of the competition and the specific rules outlined in the SAE Baja 2024 rule book.
Challenges were inevitable. We encountered several issues with the frame fittings, which required multiple redesigns. These iterations were essential as they helped us refine the roll cage to handle the stresses it would face on rough terrain. Additionally, we had to ensure our design conformed with the competition’s strict regulations, which influenced many of our design decisions and fabrication processes.
Roll Cage Final Version
Our efforts culminated in a final prototype that successfully passed all required safety tests and met the competition standards. The roll cage not only proved robust in our stress tests but also showed potential for further enhancements if more time were available. Every modification and test led to a better understanding of how to optimize the frame for both performance and safety. While also integrating new parts that have come in.
In conclusion, this project was not just about building a component of an off-road vehicle; it was a comprehensive exercise in applying theoretical knowledge to a practical, real-world challenge. It tested our ability to design, iterate, and collaborate effectively under stringent conditions—a truly invaluable experience in my engineering education.