WingGuard - Ignite Design Challenge Formula SAE

A high-performance, rules-compliant rear wing mounting system for Formula SAE vehicles, utilizing a lightweight carbon fiber bracket-and-strut architecture to ensure aerodynamic stability and safety.

Comment

Inspiration

The project was inspired by the need for Formula SAE (FSAE) teams to balance high-performance aerodynamics with strict safety and regulatory standards. We aimed to create a solution that moved away from heavy, traditional welded mounts toward a modular, professional-grade system accessible to student teams.

How We Built It

We developed a modular bracket-and-strut architecture that connects the rear wing to the vehicle's rear chassis.

Design: We used a dual-bracket configuration to provide redundant load paths, distributing forces across multiple attachment points.

Adjustability: Integrated rod end bearings allow for fine-tuning the wing’s angle of attack without full disassembly.

Fabrication: Brackets were designed with a 0°/90°/±45° carbon fiber layup schedule and CNC-trimmed for precision.

Challenges Faced

Regulatory Compliance: Interpreting nuanced 2026 FSAE rules for "Critical Fasteners" and positive locking mechanisms required extensive research.

Optimization: We had to iteratively redesign the bracket geometry to find the perfect balance between weight minimization and structural redundancy.

Composite Manufacturing: Moving from aluminum to carbon fiber required us to master new skills in layup techniques and insert bonding to prevent composite crushing.

What We Learned

The team gained critical insights into the importance of early requirements analysis, the value of modularity in engineering design, and the necessity of maintaining conservative safety factors in safety-critical racing systems.

Built With

  • 6061-t6-aluminum
  • 6061-t6-aluminum-(tubes-and-plating)
  • and-metallic-threaded-inserts-(helicoils).-software/tools:-cad-modeling-software
  • and-metric-class-8.8-steel-(fasteners).-hardware:-steel-rod-ends-(aurora-bearings)
  • cad-modelling
  • carbon-fiber-composite
  • cnc
  • fea
  • finite-element-analysis-(fea)-tools
  • metallic-threaded-inserts
  • metric-class-8.8-steel
  • nylon-lock-nuts
  • pre-preg
  • steel-rod-ends
  • u-bolt-chassis-clamps
Share this project:

Updates