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Penn Electric Racing

Mounting tabs, manufacturing jigs, and production-ready drawings for Penn's electric race car — plus composite airfoil layups.

December 31, 2025
  • SolidWorks
  • Composites
  • Manufacturing
  • ANSYS Fluent
  • Technical Drawing

Overview

Built with Audrey Tseng and Sofia Padilla Regules.

For my work with Penn Electric Racing (PER) this year, I contributed to various vehicle subsystems — designing mounting tabs, manufacturing jigs, and generating production-ready technical drawings.

Because many of these components are deeply integrated into the full-vehicle master assembly, they’re best represented through the standalone SolidWorks engineering drawings I finalized for production — each with orthographic views, an isometric, tolerances, and material and process callouts ready to hand to a manufacturer.

SolidWorks production drawing of the front wing outer flap (rear), a curved aero element to be 3D printed in ASA — orthographic and isometric views with a Penn Electric Racing title block. SolidWorks production drawing of the front wing outer flap (front), showing the profile and mounting bosses, to be 3D printed in ASA. SolidWorks production drawing of the side wing end rib, a curved panel with a cut-out window, to be 3D printed in ASA. SolidWorks production drawing of a two-hole mounting tab in AISI 4130 steel, dimensioned for waterjet cutting from flat stock.

Composite airfoils (rookie project)

For my rookie project, I manufactured the aerodynamic airfoils via composite hand layup, then ran aerodynamic analysis in ANSYS Fluent and Luminary to refine the design.

A teammate in nitrile gloves draping a sheet of woven carbon-fiber fabric over the airfoil mold during hand layup, on a cluttered composites bench in the shop.

Laying the weave down by hand means smoothing each ply over the curved mold so it conforms without wrinkles or dry spots before the resin goes off.

The laid-up part sealed under clear vacuum-bagging film with yellow sealant tape around the perimeter and a vacuum line running in, breather fabric visible through the bag.

Once the plies were wet out, we sealed the part under a vacuum bag — yellow tacky tape around the edges, breather cloth to wick excess resin, and a vacuum line to pull the laminate down tight and compact it while it cured.