Alan
Moody
I design, validate and manufacture suspension components for Formula Student cars.
Front upright for an electric Formula Student car
The motor, planetary gearbox, brake caliper and sensors all have to live inside the wheel, so the upright can't be treated as a separate suspension part.
The whole loop is my job: geometry around the packaging envelope, redesign according to FEA results and compare against stiffness targets, GD&T and tolerance stack-ups, and drawings ready for 5-axis CNC.
EV front upright
Hub motor, gearbox and brakes packaged inside the upright: designed, analysed and put on the machine.
DWG-02
Carbon steering column
Steel mount replaced with a carbon column and aluminium bushing housing: 73% lighter, passed scrutineering.
DWG-03
Suspension clevis
Reworked from 7075 to 6061 mid-build: hand calcs, then Ansys to SF 2.0 on yield. Machined in-house, raced without failure.
DWG-04
Manufacturing & tooling
Fixtures, tooling and components: Manual mill, Manual lathe, GMAW/SMAW, metrology.
CAPABILITIES
- 01Suspension & outboard design
- 02FEA & hand-calc validation
- 03BS8888 drawings · GD&T · stack-ups
- 04SolidWorks · Siemens NX · Ansys
- 05Manual & CNC machining
- 06Welding · metrology · inspection