Duke Electric Vehicles 2025-26
Objective
Duke Electric Vehicles (DEV) is a student-led engineering team at Duke University dedicated to designing and building ultra-efficient electric vehicles. We combine innovation, sustainability, and hands-on experience to push the limits of energy efficiency and redefine what’s possible on the road. For over 15 years, we’ve competed in the Shell Eco-marathon, an international competition for energy-efficient vehicles, showcasing our designs and engineering excellence on a global stage.
As a member of the Kinematics Team, I work to design and manufacture our vehicle’s custom front axle and steering system.
Takeaways
Outcome
During the fall semester, I designed multiple components of the front axle system in SolidWorks and successfully integrated them into the vehicle’s full mechanical assembly. In the spring, my team members and I worked tirelessly to manufacture and assemble our vehicle, ultimately earning DEV’s first ever Technical Inspection pass in the Urban Concept division!
Working hard…
Skills
CAD Modeling & Simulation (SolidWorks)
Design for Manufacturing (DFM)
Machining (3-Axis Mill, Lathe)
Mechanical System Design
Cross-Functional Collaboration
Engineering Documentation
I can’t share too many specific technical details about my work, but my primary contributions for the 2025-26 season included:
Conducting thorough research into front axle systems and developing a deep understanding of the system’s components, mechanisms, and design requirements
I had no prior knowledge of/experience with cars before this experience. If you asked me what rack & pinion, steering knuckle, or spindle was, I definitely couldn’t have told you!
Designing custom steering knuckle mounts in SolidWorks
The steering knuckle mount supports the entire wheel assembly, allows the wheel to pivot, and attaches the assembly to the car’s chassis
Developing CAD models of pre-bought components, including our rack & pinion and kingpin, to insert in our SolidWorks master assembly
Machining 10+ custom aluminum components using both manual and CNC mills and lathes as well as a Waterjet
I had also never machined before joining DEV!
Designing and 3D-printing a support to support the steering column, holding it securely in place while also still allowing it to turn smoothly
Assembling, testing, and fine-tuning the entire front axle assembly
Researching and deciding on the optimal way to attach all aluminum axle components to the carbon fiber chassis
Front axle assembly coming together!
Front axle attached to the car
Finishing touches at competition
or hardly working??
Positioning the rack & pinion to minimize energy losses when turning
First machined prototype of the steering knuckle mount
Being a member of DEV has been an incredibly valuable and rewarding introduction to electric vehicles and the full scope of engineering required to design a car for the Eco-marathon! Throughout the fall semester, I focused on developing a deep understanding of the front axle system, conducting research and translating those insights into custom components modeled in SolidWorks. During the spring semester, I manufactured numerous front axle components and collaborated across sub-teams to assemble our final vehicle.
Being a member of DEV has strengthened my SolidWorks proficiency, machining skills, and given me hands-on experience working with large-scale assemblies. It has also reinforced the importance of conducting thorough research before diving into design decisions and the importance of effective cross-functional communication in developing a cohesive system, as I’ve had to collaborate closely with DEV’s various electrical and mechanical sub-teams.