Composite Weight Reduction for Aerodynamics Package of a Formula SAE Vehicle

This project investigates lightweight composite manufacturing methods to reduce the mass of Gaucho Racing’s aerodynamic package for the GR26 Formula SAE vehicle. The study evaluates alternative materials and fabrication techniques, specifically pure carbon fiber laminates, lower-density foams, and the use of Peel Ply to minimize excess resin retention. Prototype components manufactured using Mylar-based layups will be compared against Peel Ply-assisted layups to quantify weight savings and structural performance differences. The objective is to develop a repeatable, weight-efficient composite process that significantly reduces the aerodynamic package’s mass while maintaining adequate stiffness and manufacturability.