• Keeping aero parts from hitting the ground

• Unexpected loads and directions

• Stopping oscillation

• Making or buying cables

Many of the common issues with FSAE halfshafts stem from these problems:

• Extreme misalignment between differential and wheel hub

• Tripod housing depth too shallow or too deep on either or both ends

• Contaminants in grease
  

• Bearing Style Selection

• Misalignment Limits

• Installation

• Travel, Backlash, Deflection

• Bearing Stiffness, Contact Area, Degrees Of Freedom

• Link Stiffness, Strength, Weight

• Engineer a strong battery lifespan

• EV Efficiency is as important as mass, downforce, drag, power, and mu.

• Create tools for drivers to manage energy

• Add regenerative braking later

To manage priorities, ask four questions about every design decision, in this order: 1. Is it legal or illegal? 2. How does the change affect reliability or repeatability? 3. How does the change affect overall vehicle performance over a lap? 4. What are the drivability effects?

The most common barrier between your team and your performance goals is reliability. These design best practices are intended to help you create strong, stiff, and light mechanical designs. Every design requires tradeoffs, and this list is not intended to be a set of absolute rules; but it will help you identify common design strategies to follow, pitfalls to avoid, and will inform your design decision making.

Steps to reduce the chances of valve-piston contact or crank bearing failure. The importance of cooling and RPM limits.