PROJECT TYpE: University group project
Design, Build, and Test Project
Project Impact
Bridging theoretical mechanics with hands-on fabrication, this project delivered a high-performance wooden truss capable of exceeding 1kN of force for a total cost of just £4.90. Through disciplined cost tracking, workshop safety, and precise Fusion 360 modelling, our team transformed a strict design specification into a compliant, production-ready structure that met BS 8888. standards.
THE CHALLENGE
Balancing smart truss structuring with low cost.
In this Design, Build, and Test Project, our engineering team was tasked with designing, building, and testing a wooden structure that meets strict geometric specifications—including a 520mm length, a 150mm width, and a height between 120mm and 150mm. The structure needed to withstand a minimum vertical test load of 1kN over a 400mm span, be documented through formal BS 8888 drawings and a health and safety risk assessment, and strictly adhere to a maximum material budget cap of £5.00.
THE SOLUTION
Fast-paced conceptual design, iterative CAD modelling, & FEA testing.
To address the structural constraints under tight workshop deadlines, our team focused on synchronised collaboration and efficient material distribution. Working to tight deadlines on initial design drafting, we were able to quickly move on to CAD modelling. Due to our fast work, we were able to complete FEA testing on our structure, ensuring it was we optimised to support a 1kN point load over a 400mm span. Through continuous communication and clear task delegation, we streamlined assembly in the workshop, producing the physical model that ultimately passed the stress testing and gained a First Class overall grade.
Lead CAD Designer
Engineered the complete 3D structural model in Fusion 360, designing a symmetrical triangular framework tailored to fit within 520mm x 150mm x 150mm envelope constraints. Authored the official BS 8888 documentation package at 1:3 scale with a 0.2mm global tolerance, producing isometric views, third-angle projections, and an itemised parts list for production.
Financial Planning
Took responsibility for material costs using unit pricing for Jelutong wood members, M4 hardware, and self-tapping screws. By evaluating cost alongside designing in Fusion360, I was able to create a design that optimised the strength of our structure, successfully capping total material expenditure at £4.90; under the project’s strict £5.00 cost limit.
My Role & Responsibilities
How I contributed to the project...