Design

The design process for Odyssey starts with designing the outer shell of the car. Odyssey is designed in SolidWorks around a mock-up of a human figure, and changed depending on the results of Computational Fluid Dynamics (CFD) tests run on the model. Once the shell is designed two models are created at 1/10 scale for wind tunnel testing.

Once the shell is designed the frame of Odyssey is modeled. The frame is modeled to fit inside the shell with a tolerance of 1/8 inch. Once the frame is completely modeled in SolidWorks Finite Element Analysis is used to ensure the frame can withstand collisions and rolls.

To ensure the frame will fit the driver a PVC mock-up is created and tested.

Construction of the shell

A plug (shaped like the body of Odyssey) is machined out of Styrofoam and covered with spray core. The plug then has to be hand sanded down to 400 grit sandpaper, painted and waxed. Once the plug is smooth it is covered with a vacuum infusion of fiberglass and epoxy to make the female (inverse of the car) mold. A wooden frame is constructed to hold and support the mold while working with it. The mold then is sanded, painted and waxed. The final step of constructing the shell of Odyssey is to use pre-impregnated carbon fiber and honeycomb material to create the body from the mold. The shell and mold are baked to harden the epoxy, then all the pieces are fitted together and glued.

Construction of the frame

The frame of Odyssey is constructed of Titanium tubing with the intent of protecting the driver and supporting the suspension while keeping the weight as low as possible.

The first step to constructing the frame is to create a jig to hold the pieces while welding. Without a jig pieces will warp and become misaligned during the assembly process. The jig used for Odyssey is made of mild steel. Once the jig is assembled the Titanium tubing is cut to size, and the ends shaped to fit into each other. The pieces of the frame are bolted to the jig and welded with a TIG welder.

Steering and Suspension

The steering and suspension of Odyssey is the most complicated mechanical designs in the whole car. They are designed to eliminate bump steer and to protect the driver and the solar cells. The Steering and Suspension are made of Titanium components to keep the weight down and strength up.