FSAE Battery Pack Mounts Jig

CAD & SolidWorks Hands-On & Shop Experience Mechanical Design & DFM

How this project demonstrates each skill

Dual-purpose welding jig with a single base plate and interchangeable inserts for aluminum TIG and steel weld configs. Had to interface with a large assembly and think through positional tolerances across multiple parts.

Hands-On & Shop Experience

Skill

Built the jig for accumulator mounting.

Mechanical Design & DFM

Skill

Machine shop work, bending metal, coordinating with welders.

Photos

Teammate TIG welding on the aluminum accumulator enclosure, clamped to the jig baseplate — TIG welding the aluminum enclosure, clamped to the jig baseplate

Baseplate with interchangeable inserts visible under the enclosure — Single baseplate with swappable inserts. Same fixture handles aluminum TIG and steel welds.

Detail of mount tabs indexed against the inserts, holding position during weld

Finished enclosure with tabs welded in place, still on the jig — Finished enclosure on the jig after steel-insert pass