Horizon Racing (F1 in Schools)

As the Strategy Head at Horizon Racing, my role spanned both core technical engineering and project management. I worked at the convergence of design and execution—leading the development of our miniature F1 car while simultaneously managing the structural and logistical components of the team’s deliverables. Horizon Racing competed in the STEM Racing India Nationals, and my responsibility was to ensure that the car was engineered to be not only fast and compliant, but also aligned with the broader project timelines, risk protocols, and strategic objectives.

Engineering Design and CAD Modeling

The car’s design process began with intensive CAD modeling in Autodesk Fusion 360. I constructed the initial chassis and aerodynamic geometry through a mix of parametric sketching and freeform surface modeling. Key components such as the front wing, side pods, and rear structure were designed to meet both performance and regulatory constraints while allowing for manufacturability through additive processes.

The modeling process included:

Multi-body modeling with split features for modular testing and adjustment
T-spline manipulation for organic surface transitions and flow optimization
Filleting and draft analysis to meet drag reduction and manufacturability targets

Once CAD models were validated dimensionally, I rendered the vehicle using Blender, applying high-resolution materials, HDRI environments, and layered passes to produce visuals for documentation, portfolios, and sponsor presentations.

Wind Tunnel Testing and Aerodynamic Analysis

To test aerodynamic performance, I designed and built a wind tunnel setup capable of controlled airflow and smoke visualization. This allowed us to directly observe airflow behavior over critical sections of the car such as the splitter, side pods, and diffuser.

We supported this with CFD simulations run in Fusion 360’s cloud solver. Using flow simulation data, I was able to validate aerodynamic behaviors observed during physical testing and use the results to optimize the design in subsequent iterations.

This phase involved:

Identifying and correcting vortex-heavy zones using tuft testing
Adjusting component curvature based on drag coefficient comparison
Streamlining flow detachment zones to reduce wake turbulence

3D Printing and Manufacturing Workflow

I led the 3D printing workflow for the car’s components, translating digital models into tangible prototypes with high dimensional accuracy. Using both FDM and resin printing platforms, I sliced the geometry in Cura and Chitubox, strategically orienting parts for strength and print cleanliness.

I oversaw all aspects of the print-to-fit pipeline:

Print orientation planning and support minimization
Shell thickness tuning and infill optimization for lightweight strength
Post-processing including sanding, resin coating, and part alignment

We printed multiple car variants and component swaps to assess design changes and validate fits before proceeding with the final race model.

Testing, Fitment, and Launch Consistency

To ensure precise wheel alignment and reduce rolling resistance, I designed a laser-based axle alignment rig, which helped align the car’s axles and wheel planes with sub-millimeter tolerance. I also ran rolling resistance tests comparing different wheel hub materials and bushings, using a custom-built ramp and time gate system.

Additionally, I coordinated CO₂ launch testing using infrared gates to assess consistency across multiple runs and compare launch response across varying car weights and balance distributions.

Project Management and Strategic Planning

Alongside technical development, I was responsible for high-level project management. I developed and maintained the team’s Work Breakdown Structure (WBS), created the Gantt chart for engineering and enterprise deliverables, and populated the team’s Risk Register.

My responsibilities in this area included:

Mapping out critical paths and engineering sprints for design and testing
Mitigating delays through schedule buffers and pre-emptive risk assignment
Synchronizing deadlines across engineering, portfolio writing, and verbal presentation prep

This integration of planning and technical execution helped create a highly responsive workflow, where prototyping, feedback, and documentation remained tightly synchronized throughout the build cycle.

Conclusion

This project challenged me to move fluidly between hands-on technical work and high-level coordination. From aerodynamic modeling and CFD testing to physical manufacturing and documentation control, I contributed to almost every major technical milestone while maintaining strategic alignment with our competitive goals. The experience has deepened my skills in real-world CAD, iterative prototyping, precision testing, and structured project management.