Carbon Fiber CV Tripod Axle Design: Husker Motorsports Formula SAE

The 2024–2025 HMS Formula SAE senior design team successfully reduced axle system weight, cost, and improved manufacturability using a bonded tripod joint and ±45° intermediate modulus carbon fiber tube. The final design was validated on HMS 25, with no failures under rigorous testing. Budget:/="/"> Total project cost was $1,165.64, exceeding the initial $1,000 target due to unanticipated test rig expenses. However, per-axle production cost was reduced from $525.31 to $383.37 through in-house manufacturing, use of on-hand epoxy (DP460), and switching to cost-effective 7068 aluminum. The axle-specific cost was $766.74. Timeline:/="/"> Despite early delays from building a torsional testing rig and ordering the correct carbon tube, the team met all deadlines by overlapping tasks, extending work hours, and using contingency plans. Final manufacturing was completed by April 30, 2025. Successes: Weight: 43% reduction (2.3 lbs → 1.3 lbs/axle) Cost: 37% per-axle reduction Manufacturability: Fully in-house; reproducibility rated 4/5 Testing: Failures occurred in the tube, not the bond, validating adhesive reliability Documentation: Comprehensive design review documents were prepared for future teams and FSAE judges The design was implemented successfully on the car, offering a robust, lighter, and more cost-effective alternative to previous steel axles.