02

Project 02

FSAE Cooling Sleeves

Custom cooling jackets for FSAE electric in-hub motors, optimized with parametric CFD in Ansys Fluent and designed for metal 3D printing.

Ansys FluentCFDMetal 3D Printing

Overview

To improve thermal performance, I engineered custom cooling jackets for our FSAE electric in-hub motors. Utilizing my experience in CFD and Fluid Dynamics, I conducted parametric simulations in Ansys Fluent to optimize heat dissipation and designed the final parts for metal 3D printing, ensuring both peak performance and manufacturability.

Gallery

Metal 3D-printed cooling jacket with internal cooling features
The metal 3D-printed cooling jacket, fresh off the printer
Cooling jacket installed over the in-hub motor with coolant fittings
Installed over the in-hub motor, plumbed and ready to run
Timeline
  1. May – AugDesign ideation / preliminary design
  2. Aug – OctDesign + validation
  3. Oct – FebManufacturing!
  4. Feb – MarIntegration
  5. Mar – MayTesting
  6. May – JuneCompetition!
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