These components were designed to integrate with a 2-person human-powered vehicle to compete in NASA’s Rover Challenge
This annual off-road event draws about a hundred teams from around the world to compete to build the lightest, fastest rover.
Weighing in at 99 pounds fully equipped, our team's vehicle was the lightest overall at the 2018 competition by a margin of over 50 pounds.
My role:
I was chiefly responsible for the design of composite parts, including the wheel, seats, fenders, and leaf spring. I also assisted with brazing/welding of the frame, design and fabrication of the handlebars and center folding coupling, and machining of steering components.

Final wheel design:
Per NASA's rules, teams are required to design and fabricate their own wheels. Pressurized air is prohibited.
Our team sought to improve upon previous designs to achieve a lighter wheel that minimized issues with impact steering, rolling resistance, and lack of stiffness in previous versions.
Wheel process:
1. Styrene half-scale mockup  /   2. Initial carbon half-scale model  /  3. Revised carbon half-scale model with stretched tread  /  4. Final wheel model patterns to be CNC cut in MDF - note concave version on right  /  5. Pulling patterns from a fiberglass mold made from CNC pattern, coated and with steel tool in center for forming the hub  /  6. Layup guide graphic to communicate layup process between team members  /  7. Trimming a wheel half to true  /  8. Prepping to seam the two halves together at the rim
Final seat design:
The fabrication of the seat posed a unique set of challenges. The seat is essentially a 12"+ lever which encounters immense force from the riders--especially when pedaling up inclines. 
Full-scale foam fit models were developed to find a comfortable seating solution.
The final product weighs about 1 pound.
Seat process:
1. Mockup jig to test rider position and seat angle  /  2. Foam seat fit model  /  3. Carving the final seat pattern   /  4. Final seat pattern  /  5. Laying up a test seat with carbon fiber
Folding, brake testing, and riding up stairs:
(Per competition rules, the vehicle must fit within a 5 foot cube space for transport, hence folding)
At the competition:
Our rover was the lightest vehicle at the competition in 2018, and performed very well. It was poised to finish near the top of the field, but unfortunately experienced a minor mechanical failure near the end of the first day's run. An aluminum rod end joint snapped, suspected to have fatigued over time. Although our team quickly recovered the rover and was ready to compete in the second day's race with upgraded hardware, NASA cancelled the race due to inclement weather. 
Check back next year for updated results!

other work