Assessfy Capstone Lab Advanced 6 milestones 100 marks

Design, Fabrication, and Analysis of a Lightweight Composite Chassis for Electric Kart ...

Branch: Automobile Engineering Type: Industry-applied final-year Major Project Standard: Mumbai University Rev-2019 'C' Scheme (Major Project I + II) Group: up to 4 students Assessment: 6 review-based milestones (100 marks)

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About this project

Design, Fabrication, and Analysis of a Lightweight Composite Chassis for Electric Kart Applications

Objective: To design, fabricate, and validate a cost-effective and lightweight composite chassis for an electric kart, optimizing structural performance and manufacturability for Indian conditions.

Background: The growing demand for electric mobility in India has highlighted the need for lightweight yet robust chassis solutions, particularly for e-karts used in education, racing, and urban mobility. Traditional steel chassis are heavy, reducing energy efficiency and limiting performance, which affects user groups such as student teams, small-scale manufacturers, and racing enthusiasts.

Proposed Solution: This project aims to develop a composite material-based chassis using glass fiber reinforced polymer (GFRP) and locally available fillers, optimized through CAD and finite element analysis (FEA) for structural safety and weight reduction. A full-scale prototype will be fabricated employing vacuum infusion or hand lay-up techniques, balancing cost and manufacturability for the Indian market.

Key Deliverables: The deliverables include detailed CAD models, FEA reports (ANSYS/Altair HyperWorks), a fabricated composite chassis, physical testing (static and dynamic load tests per IS 12239), integration with a standard e-kart powertrain, and documentation. The working model will be presented via a live demonstration under real-world load scenarios.

Impact & Scalability: Adoption of lightweight composite chassis can increase e-kart energy efficiency by up to 15%, promote local manufacturing, and support the Make in India initiative. The methodology is scalable to other low-cost EVs, improving sustainability and performance in Indian urban mobility.

Milestones

1. Synopsis & Problem Definition (Stage-I Review-1)

10 marks 21d

Submit an approved synopsis outlining the problem, objectives, and expected outcomes, reviewed by faculty and industry mentor.

2. Literature / Market Survey & Requirement Analysis (Stage-I Review-2)

12 marks 30d

Deliver a comprehensive survey of existing chassis solutions, materials, and market needs with a formal requirement specification, evaluated through a seminar and report.

3. System Design, Methodology & Cost Analysis (Stage-I close)

18 marks 35d

Present detailed CAD design, material selection rationale, FEA simulations, and a bill of materials with cost analysis, assessed during a design review.

4. Implementation / Fabrication of Working Model (Stage-II Review-1)

22 marks 38d

Complete the fabrication of the composite chassis and basic assembly, documented with process photos and initial quality checks, reviewed by the project panel.

5. Testing, Results & Validation (Stage-II Review-2)

22 marks 34d

Conduct static and dynamic load tests, compare results with FEA predictions, and validate against IS 12239 standards, with findings presented and reviewed.

6. Report, Paper & Demonstration / Oral Defense (Stage-II final Oral & Practical)

16 marks 30d

Submit the final project report, technical paper, and demonstrate the working model with oral defense before the examiner panel.

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Skills you'll learn

CapstoneFinal-year projectMajor projectAutomobile EngineeringComposite material selection and structural engineeringCAD modelling and finite element analysis (SolidWorksANSYS/Altair HyperWorks)Material lay-upvacuum infusionand fabrication techniquesIntegration of mechanical subsystems with electric powertrainStatic and dynamic chassis testing (per Indian Standards)Team coordination and project managementTechnical report writing and oral presentation

Tools used

SolidWorks or CATIA for 3D CAD modellingANSYS or Altair HyperWorks for structural FEAVacuum infusion setup or hand lay-up toolsUniversal Testing Machine (UTM) for chassis testingGlass fiberresin systemsand local fillersStandard e-kart components (wheelsaxlespowertrain)IS 12239 (Indian Standard for vehicle chassis strength)

Prerequisites

Strength of Materials / Mechanics of MaterialsAutomotive Chassis and Body EngineeringComposite Materials and Manufacturing ProcessesComputer-Aided Design and Analysis

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