The new FSAE regulations for 2015 have challenged the Monash Motorsport Aerodynamics team to create new and innovative designs for M15. With the introduction of a more limited packaging space, must notably containing the rear wing within 1.2m from the ground and between the rear tires, the team set some ambitious targets and produced more creative designs to meet these goals.

In order to implement these ideas, the team had to investigate new methods of manufacturing the aerodynamics package for this year. The complex shapes designed, such as the 3D front wing flaps allowed utilisation of the CNC machine to cut flaps from foam, generously provided to us by Australian Urethane & Styrene, which were then laid up on. The result proved to be desirable and is an exciting new discovery for the team, allowing for more interesting shapes and a lightweight product.

The aerodynamics team have also moved to implement more hollow wings elements than ever before. Thanks to our sponsors Laser3D and Form A Sign who cut MDF moulds for the 2015 aerodynamics package, we were able to manufacture both female and male moulds. The transition into manufacturing hollow elements provided new challenges but also allowed a more ideal surface finish.

With various new manufacturing methods developed this year, the team is excited to take the new designs to the Formula SAE-A competition in December and further expand and improve on these new manufacturing methods for the future.

Shannon Chen, Aerodynamics Engineer