Carbon Fiber Nose Cone
This project involved the design and manufacturing of a carbon fiber nose cone for a Formula SAE vehicle. The focus was on achieving accurate fitment with the chassis and impact attenuator while producing a lightweight component with a high-quality surface finish.
Objectives
- Design a nose cone with precise integration to the frame and impact attenuator
- Develop a manufacturable composite process using a CNC foam plug mold
- Achieve a smooth, visually clean carbon fiber exterior
Surfacing & Mold Design
The nose cone geometry was surfaced in SolidWorks, with emphasis on smooth curvature transitions to promote good fiber drapability and a clean final appearance. Fitment to the chassis and impact attenuator was carefully controlled through reference geometry.
- Surface modeling used to ensure continuous curvature
- Interfaces designed for accurate alignment with surrounding structures
- Draft angles incorporated to facilitate mold release
Composite Manufacturing
A plug mold was manufactured from 4-inch-thick CNC-machined foam blocks, bonded together to form the full mold geometry. The nose cone was produced using a wet layup process over the foam plug.
- 2×2 twill weave carbon fiber selected for improved drapability
- Wet layup with resin application
This project did not include CFD or FEA analysis, as the primary goal was to validate the manufacturing approach, fitment, and surface quality rather than aerodynamic performance.
Post-Processing & Final Finish
After curing and demolding, the nose cone underwent post-processing to improve surface quality and seal any dry spots in the laminate. The final finish was achieved through sanding and clear coating.
- Surface sanding to remove imperfections
- Clear coat applied for sealing and gloss finish
- Final fit check performed on the vehicle
Additional Images
