Shubham Iyer

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Composites and Thermoforming

CWRU Motorsports (Baja SAE) · 2025 to present

Not everything on the car is machined. I've worked on three composites and plastics jobs for the team.

Thermoforming

The team bought a vacuum thermoformer, and I set it up and ran its first job. That run produced a spare set of Kydex bodywork panels for SR26.

The team's vacuum thermoformer.
The team's vacuum thermoformer.
One of the forming molds.
One of the forming molds.
A Kydex sheet after forming, before trimming.
A Kydex sheet after forming, before trimming.
The formed sheet from above. The mold's notched outline shows through.
The formed sheet from above. The mold's notched outline shows through.

The carbon fiber seat

I worked on the carbon fiber layups for the SR26 seat. For SR27 I'm comparing the 0/90 woven fabric we used against unidirectional fiber.

Carbon fiber for the driveshaft and steering column

I'm building a cantilever bend test fixture for carbon fiber tubing, and planning the torsion tests that follow it. Those results will decide whether carbon fiber replaces metal in the driveshaft and steering column.

Next project: Embedded AI Desk Assistant →