FSAE Pedal Box Assembly Manufacturing Project

Worked with a team of 5 mechanical engineering students in designing and planning the manufacturing of a pedal box assembly for formula-style race cars. Utilized SolidWorks to model the assembly of 5 unique parts - frame, clevises, rails, carriages, and pedals.

Developed complete 2D drawings with GD&T specifications. Formulated process layouts and travelers for CNC milling, manual milling, bending, and other operations to manufacture 200 assemblies per year. Estimated $100,000 annual revenue based on a target cost of $500 per assembly. Emphasized design for manufacturing and assembly to optimize machinability, reduce material waste, and shorten production time.

Gained hands-on experience in manufacturing engineering concepts including operation sequencing, fabrication methods selection, cost analysis, quality control, and planning for scalable production.