Composite FSAE Body Work
The Goal
Manufacture Composite body work for an FSAE race car
The Process
The Formula SAE bodywork was manufactured entirely from carbon fiber using a combination of positive and negative mold techniques to achieve accurate geometry and lightweight construction. The nose cone and topper were produced in negative molds, allowing the exterior surfaces and aerodynamic profiles to be defined directly by the mold surface. The sidepods were fabricated using positive molds and vacuum bagged against flat tooling to improve fiber consolidation and laminate consistency. Each component was laid up with carbon fiber reinforcement and resin, then cured before being removed from the molds. After demolding, the parts underwent post-processing including trimming, sanding, and surface finishing to refine edges and improve surface quality. Finally, the completed components were vinyl wrapped to apply the vehicle livery and provide a consistent finished appearance.
Nose Cone Mold Process
CNC Foam mold
High density foam was machined in slices to stack and form the mold. Gaps in the slices were filled with mold filler and sanded flush.
Primer & Sand
The mold was sprayed with primer and sanded with progressive grit until a smooth surface finish was achieved.
Mold Preparation
Flex seal was utilized as a mold sealant with mold release to allow for removal of the finished part.
The Result
The final result was a full carbon fiber bodywork package for the HR25, including the nose cone, topper, sidepods, and body panels. Using a mix of negative molds for high-accuracy aerodynamic surfaces and positive molds for more adaptable geometries, I was able to better understand how mold selection directly impacts surface quality, manufacturability, and overall finish. Vacuum bagging improved fiber consolidation and consistency across parts, resulting in lightweight and structurally sound components. After trimming, finishing, and vinyl application, the bodywork came together as a cohesive, competition-ready package that balances performance with a clean, professional appearance.
