Inside Elon University’s Clark Prototype Lab, a team of dedicated student engineers is making waves by designing and constructing an electric race car from the ground up. This ambitious endeavor, known as Phoenix Racing, represents Elon’s exciting foray into the world of competitive motorsports and serves as a dynamic Race Car Program for aspiring engineers.
Part by meticulous part, the members of Phoenix Racing – a burgeoning engineering initiative at Elon University – are immersed in the intricate processes of machining components, expertly welding the chassis, innovating the driver’s interface, and developing the complex circuitry necessary to power a high-performance electric Formula-style vehicle. Their ultimate goal is to pit their creation against designs from leading international engineering programs in the prestigious Formula SAE Electric competitions. By participating in Formula SAE, Phoenix Racing is not only setting a new benchmark for Elon’s engineering program but also significantly enriching the educational experiences for future engineering students.
“I believe many underestimate the magnitude and excitement of undergraduate students undertaking a project of this scale,” remarks Nicholas Muller ’24, co-founder and team principal of Phoenix Racing. “None of us started knowing how to build a complete race car, yet we are collectively making it happen. This project is deeply significant, both for us personally and for the broader engineering program at Elon. It’s a powerful demonstration of what Elon engineers are capable of achieving.”
Phoenix Racing is aggressively targeting the June 2024 FSAE Electric competition near Detroit as their debut event. To reach this milestone, they are actively securing funding from sponsors and partners to refine their race car’s design to outperform last year’s benchmark time set by Georgia Tech: completing a 75-meter sprint in just 3.6 seconds. The previous FSAE Electric competition saw participation from seventy teams, with top rankings achieved by universities like Carnegie Mellon, University of Washington, and Virginia Tech.
Precision engineering is paramount, and the advanced facilities within the Innovation Quad’s machine shop and prototype labs are instrumental in making Elon’s race car program a reality.
“These Formula 1-inspired electric vehicles offer unparalleled acceleration, exceeding that of commercially available sports cars,” Muller explains. “They can achieve 0 to 60 mph in approximately 2 seconds, which necessitates extremely precise design and the use of top-tier, often expensive, components to ensure both safety and vehicle robustness.”
This electric car project perfectly encapsulates the hands-on, experiential learning ethos of Elon’s engineering program. It demands the practical application of intricate technical skills, fosters intense collaboration and communication throughout the design and fabrication phases, and embodies an entrepreneurial drive, notes Scott Wolter, Associate Professor and Chair of the Department of Engineering at Elon University.
“Conceptualizing a race car is one thing, but the true learning emerges when you engage in the design and build process. That’s when the underlying engineering principles truly come to life,” Wolter elaborates. “The beauty of FSAE competitions lies in this direct application of classroom knowledge. This experiential learning approach is central to the educational environment we cultivate for our students at Elon.”
Formula SAE competitions, initiated in 1981, challenge undergraduate and graduate student teams to design, construct, and demonstrate small, open-wheel, single-seat race cars. Judgments are based not only on speed but also on innovative design elements that enhance acceleration, energy efficiency, and endurance. Participation in FSAE is a hallmark of strong engineering programs. Established institutions often boast teams of over 100 members, benefiting from decades of accumulated design knowledge and prototyping expertise passed down through generations of students.
Under the leadership of Muller, Henry Echt ’24, and Jack O’Donnell ’25, Elon’s Phoenix Racing team includes 18 students from diverse academic backgrounds and is advised by Engineering Lab Manager Matthew Banks. Elements of this inaugural race car design are integrated into the year-long Senior Projects in Elon Engineering Design (SPEED) course. In this course, senior students tackle critical subsystem design and construction, focusing on the human-machine interface and ergonomic considerations within the cockpit as their capstone project.
Echt, pursuing a double major in computer science and communication design, leads the drivetrain team. After extensive experimentation, he and Muller successfully activated the electric motor during an intense late-night session in February, marking a significant milestone for the race car program.
“What I value most is the daily intellectual challenge,” Echt shares. “The varied discussions and problem-solving we engage in provide me with a richer, more dynamic perspective that enhances my academic studies.”
Ben Trainum ’24, a team member double majoring in engineering with a computing concentration and computer science, is energized by the advanced design challenges. He has dedicated countless hours to designing the car’s sophisticated rechargeable battery system, acquiring skills and a depth of expertise far beyond traditional coursework.
“These types of complex tasks are typically assigned to graduate-level engineers. Through this race car program, I am independently learning and applying advanced concepts in high-voltage battery pack design, CNC machining, manual machining, and gaining substantial mechanical design proficiency,” Trainum explains.
Team members have actively built relationships with experts in the automotive sector and at other academic institutions. The race car chassis was constructed over the spring and summer periods with crucial support from the welding program at Alamance Community College.
Beyond prototyping and engineering, the team is heavily involved in developing sponsorship pitches and nurturing relationships with business partners. Phoenix Racing has successfully raised over $24,000 of their $40,000 goal needed to be competition-ready by May, attracting an impressive array of sponsors, including Sandvik Coromant, Bravo Team, AKG of America, Corvid Technologies, and ACI Automotive and Performance.
Significant tasks remain before the race car is fully prepared for competition. The team must complete the bodywork, finalize the power packs and battery management system, complete the intricate electrical system, and fabricate the suspension.
However, the countless hours spent in the Innovation Quad’s machine shop are demonstrably advancing the project towards the June 2024 competition deadline.
“For me, the most rewarding aspect is the collective identity we’ve forged,” Echt concludes. “Everyone is united by the goal of building this exceptional race car, getting it to Detroit, and showcasing what a dedicated, lean team can achieve.”
Individuals interested in supporting or joining Elon University’s race car program, Phoenix Racing, are encouraged to reach out via email at [email protected].
