Figure 2: Function Decomposition Ideas

Figure 3: Comprehensive Concept Designed by Om Chaudhari

Project Organization and Virtual Prototyping

Our team followed a structured, iterative design process from early research to a validated prototype. We started by building a clear project plan to keep priorities and timing realistic. I helped create a CPM to identify the critical tasks, then we translated that into a Gantt chart that made ownership and deadlines obvious for both individual and team work. From there, we gathered requirements through documentation review and benchmarking existing solutions, then turned what we learned into measurable constraints, performance targets, safety margins, and manufacturing limits, which guided every decision we made.

During concept generation, we used function decomposition to break the system into manageable sub-functions, then explored solutions for each using morphological charts. Figure 2 shows my function decomposition and the early concept space we mapped out. To make the ideas feel "real" quickly, I produced SolidWorks models to visualize key mechanisms, especially a clutch concept to control power delivery shown in the SolidWorks Models Page. We compared options using a Pugh chart and a weighted decision matrix (WDM), scoring concepts on factors like design complexity, cost, reliability, and steering performance. That structure kept discussions productive and helped us choose a direction that was ambitious but still buildable. Figure 3 shows a comprehensive sketch of my concept which was part of the concept evaluation phase.

For prototyping, we blended virtual and physical iterations. On the virtual side, we used SolidWorks to test steering layouts and packaging, and I built Excel-based calculations to estimate torque output and expected top speed using motor data. On the physical side, we moved fast with 3D-printed parts and off-the-shelf components to check fit, assembly, and manufacturability early. To stay aligned, we kept consistent meeting minutes and tracked deliverables each work period, which made it easier to close the loop between test results and design updates. That tight cycle between digital models and hands-on prototypes is what let us iterate quickly without losing control of the overall system.

Figure 4: Plastic Chassis Beta Prototype

Video 1: Hill Testing With Payload

Technical Challenges & Reflection

Team-wise, the biggest challenge was keeping design, fabrication, and testing moving in sync. We solved that by being deliberate with communication: quick check-ins, clear task ownership, and making sure test results actually fed back into the next iteration instead of getting lost in the shuffle. That rhythm made the project feel fast-paced in a good way—busy, but controlled.

In the end, we delivered a working vehicle that met the project requirements and held up under real testing. Our results were strong in areas like storage capacity and torque performance, and the final design reflected the trade-offs we made intentionally, not by accident. More importantly, I walked away with a clearer understanding of the full engineering cycle: requirements → concepts → prototypes → testing → iteration, and how quickly your early assumptions can change once you collect real data.

And honestly, it was fun. There's something satisfying about building with a team where everyone brings a different strength, then watching all the pieces come together into a prototype that actually works (and works better after you've broken a few things and learned from it).

Physical Prototyping and Testing 

As we moved into fabrication and assembly, I took ownership of the details that make a build actually come together. I managed our fastener selection and organization, helped design and build brackets for the four-bar linkage and chassis, and supported assembly on the final iteration. I also worked on electrical integration, mounting and wiring the battery packs, receiver, servos, and DC motors directly onto the chassis so everything was secure, serviceable, and consistent between test runs. 

Figure 4 shows our beta prototype with the plastic chassis, which was a key step in understanding how we could optimize the chassis design and how to secure it to the steering and powertrainn subsystems.

For testing and validation, we defined clear test plans with success criteria and clear test procedures. I helped conduct experiments by controlling the movement of the car and made sure to document testing through videography as a team, highlight in Video 1. That footage made it easier to spot real issues, like weight distribution affecting traction and power transfer, and to connect performance problems back to mechanical load and motor torque limits.

On the project management side, I managed expenditures and finalized the BoM of the design, ensuring that all costs were accounted for no matter how small. I also in assisted in ensuring all documentation was up to standards regarding formatting and naming.

Final Team Photo