Design Considerations
In addition to the Rules & Regulations, it's really important to think about all of the following aspect of the Challenge before you start the project, otherwise you could miss something crucial!
Design Preparation: Before beginning to design your car, you will need SolidWorks or a similar 3D CAD software package at your school/college. Also, a design template suitable for the balsa wood blank. These are available in our SolidWorks tutorial. You will also need an endless supply of ideas!
Training: CAD packages will help you draw and develop your ideas in 3D. Of course, as with most drawing packages, it takes time to learn how to use them. Your D&T teacher should be able to show you how the software works, but members of your team will need to spend some time exploring the software, so you can see what it can do and how it can help you design your F1 car.
Research: Investigate existing F1 car design, there are links to all the Formula One teams on this site and the internet is a great tool to source information about the latest developments occurring in the world of F1 and Motorsport design. Concentrate your research on areas that could help your team, for example, aerodynamics and car body designs, then try to apply the principles to your own ideas.
Testing: Your team may want to consider testing a variety of car designs, or car parts, in a real or virtual wind and/or smoke tunnel to evaluate their aerodynamic performance. To do this you will need to ask your teacher to contact your local Test Centre and book some time with their equipment or investigate if your school could buy the equipment.
Manufacturing Considerations: If your school does not have a CNC machine at school, then make sure you contact your nearest Manufacturing Centre before you start designing to see if they have any manufacturing consideration you should consider before you start desiging. Even if you do not have acess to a machine in school you can still follow the manufactruing process using a CAM software package like EdgeCAM.
Note that your car design template must be around 10mm shorter at each end, compared to the actual balsa wood block. You cannot machine the extreme ends of the balsa wood block, since they are used for attaching the CNC machine jig fixtures. Damage could occur if the cutting tool hits any of these jig fixtures. The jig is used to stop the balsa wood block moving whilst being machined. It also allows the block to be accurately repositioned, so the two separate cutting operations (one for the right side of the car, the other for the left side of the car) are performed in the correct locations. Once machined, you can smooth down the balsa wood design and finish with paint.
Note that only a limited amount of hand finishing to the body is allowed. You could also decorate the car body with any sponsorship stickers, advertising or colour schemes
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