During my second year, I led the design of a fully validated cooling system for Virginia Motorsports’ FSAE electric vehicle. The challenge was to keep the motor and inverter cool during endurance on a 95-degree day in Michigan, while ensuring long-term reliability.

I began with a month of research to establish validation and reliability goals for the new system. I performed detailed pressure drop calculations for proposed components and designed a more efficient routing layout. To model thermal performance, I built a MATLAB Simulink simulation that mapped system temperature over time under heat load assumptions. I verified these results using the Number of Transfer Units (NTU) method, confirming that the crossflow heat exchanger would provide sufficient effectiveness.

Beyond analysis, I collaborated with the electrical team to integrate sensors for data collection and monitoring. I then used Fusion 360 to model components and designed custom mounting brackets, which I later manufactured and installed on the car.

The result was a fully integrated, operational cooling system that passed technical inspection at competition and enabled data acquisition. Although the car’s EV system was unable to compete that year, the project provided a validated cooling framework and hands-on experience with simulation, design, and fabrication that will guide future vehicles.