SAURABH PAL
About me
I’m Saurabh, a mechanical engineering Master’s student at Tufts university with an expertise in the design of mechanical components, including electric motors, composite materials, complex assemblies, and structurally, thermally, or aerodynamically optimized parts. I am the founder of Tufts Solar Vehicle Project and have led the design and manufacturing of the team’s first road-going solar powered car.
TUFTS SOLAR VEHICLE PROJECT
The student-team I started that sparked my passion for engineering design.
Designing and building a road-legal solar-electric car from the ground up.
Sample Design Projects
Front Suspension
Design and optimization of suspension assemblies for a three-wheeled vehicle.
Skills: CAD of Complex Assemblies, FEA, Engineering Drawings, CNC machining, MATLAB.
Composite Chassis
Carbon-fiber composite design, optimization, simulation, and manufacturing for a structural chassis.
Skills: Composite/Anisotropic FEA, Material testing and characterization, creating composite tools and parts.
Wheel Rims
Design, simulation, and tool design of 16" metal and carbon fiber wheels
Skills: CAD, Non-linear (Fatigue) FEA, Devising test methods.
Electric Motor
Scratch-built and designed axial-flux electric motor to power the solar car.
Skills: MATLAB, Analytical Models, CAD, DFM: CNC manufacturing & casting.
Aerodynamic Shell
Design and optimisation of low-drag vehicle bodywork.
Skills: Surface Modeling in CAD, Freeform Modeling, CFD, MATLAB race modeling, DFM, Tool Design.
Battery Pack
Design and Manufacturing of a lightweight battery pack and internal wiring harness, including selection of batteries, bus bars, configuration, electronic components.
Skills: CAD, Composite processing, Thermal Analysis, High Voltage Electronics Design.
Custom Steering Rack
Project to build a custom steering rack from scratch. Limited success; A lesson in tolerances of motion systems.
Skills: CAD/Design, Manual machining, gears, motion systems, Tolerances.
Robotics Projects
Projects from classes that improved my coding and prototyping skills
Please visit the notion page linked above for some robotics-related projects done earlier in my education.