Headrest

FSAE Driver interface system.

As one of the few industrial designers in an engineering club, I was tasked with leading the complete redesign of the carbon fiber headrest structure, acheiving a weight reduction of 50%, while increasing strength by 20%.

I collaborated closely with interdisciplinary teams, learned ANSYS structural FEA, and applied DFM principles while working with pre-impregnated carbon fiber, an entirely new material for this application.

Ultra lightweight

The entire headrest system weighs just 254 grams, a significant weight reduction compared to wet carbon or aluminum alternatives. Pre-impregnated carbon fiber combines exceptional strength with minimal weight—crucial for maximizing on-track performance.

Rigorously tested

Fully rules compliant and designed to meet all safety regulations, this headrest system withstands up to 900 N of force in a rearward direction, and 300 N in a lateral or vertical direction, validated in both ANSYS Mechanical and physical stress testing.

Designed for easy maintenance

Repairability and serviceability is crucial when designing for a component that withstands wear and tear on the track. The disassembly process is simple and allows for easy part replacement.

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