Islamic University Journal of Applied Sciences

A Comprehensive Framework of Best Practices for Designing, Implementing, and Competing with a Formula SAE Race Car

Faisal Omar Mahroogi

Keywords: Formula SAE; Design for manufacturability; Vehicle dynamics; Electric vehicle.

Major: Engineering

Sub Major: Mechanical Engineering

https://doi.org/10.63070/jesc.2026.035; Received 22 April 2026; Revised 28 May 2026; Accepted 04 June2026; Available online 15 June 2026.
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Abstract
Designing and constructing a Formula SAE (FSAE) vehicle is a premier engineering capstone project. This paper presents a comprehensive framework centered on five critical pillars: strict rule adherence, systems engineering, rigorous project management, design for manufacturability, and iterative testing. By analyzing these pillars through decision matrices and process flowcharts, the framework provides actionable guidance for academic teams. A central theme is that a reliable, well-tested vehicle consistently outperforms a theoretically superior but fragile design. The study addresses both Internal Combustion Engine (ICE) and Electric Vehicle (EV) platforms, reflecting the modern landscape of the Formula Student series. Key lessons emphasize recognizing regulatory limitations, maintaining cohesive system integration, and strictly allocating time for validation. The provided resources—including comparative data tables and failure mode frameworks—serve as a modular toolkit for teams to optimize their unique programs. Ultimately, success depends on the transition from theoretical engineering to a physical prototype that can endure the rigors of competition. Regardless of powertrain choice, the core principles of feasibility and thorough testing remain the ultimate drivers of performance.
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