Inside Founders Hall’s Clark Prototype Lab at Elon University, a group of ambitious student engineers are breaking new ground, embodying the spirit of a dynamic Racing Car Program. They are not just learning theory; they are immersed in the practical world of automotive engineering, designing and constructing an electric racecar from the ground up.
Phoenix Racing, Elon’s newly established engineering initiative, is meticulously crafting each component. Students are machining parts with precision, welding the chassis with expertise, and innovating the driver’s interface and circuitry that will energize a Formula 1-style electric vehicle. Their ambitious project is geared towards competing in the prestigious Formula SAE Electric competitions, pitting their creation against vehicles from leading international engineering programs. This endeavor by Phoenix Racing is set to significantly elevate the profile of Elon’s engineering program, offering enriching, hands-on experiences for current and future students within this thriving racing car program.
Nicholas Muller 24′, team principal of Elon University’s Racing Car Program, Phoenix Racing, expertly machines parts in the Clark Prototype Lab.
“I believe many underestimate the magnitude and excitement of undergraduate students undertaking such a project,” stated Nicholas Muller ’24, co-founder and team principal of Phoenix Racing. “None of us on this team started with the knowledge of how to build a car, yet we are collectively making it happen. This project is deeply significant, both for us personally and for the engineering program as a whole. It showcases the capabilities and potential inherent within Elon engineers participating in this innovative racing car program.”
Phoenix Racing is aiming high, targeting the June 2024 FSAE Electric competition held near Detroit. To achieve this, they are actively fundraising through sponsorships and partnerships to design a car capable of surpassing last year’s winning performance by Georgia Tech – completing 75 meters in just 3.6 seconds. The previous FSAE Electric competition saw participation from seventy programs, with top rankings achieved by universities like Carnegie Mellon, the University of Washington, and Virginia Tech. Elon’s entry into this competitive arena through its racing car program marks a significant step forward.
Precision engineering is paramount, and the advanced facilities within the Innovation Quad, particularly the machine shop and prototype labs, are crucial in making Elon’s FSAE team and racing car program a reality.
“These Formula 1-inspired vehicles are engineered for unparalleled speed, exceeding the performance of commercially available cars,” Muller explained. “Their rapid acceleration – from zero to 60 mph in approximately 2 seconds – necessitates meticulous design and the use of high-quality, often expensive components, to ensure both safety and robustness. This level of rigor is integral to our racing car program.”
This electric car project perfectly exemplifies the experiential learning approach central to Elon’s engineering education. It combines the practical application of sophisticated technical skills, fosters crucial collaboration and communication in design and fabrication, and cultivates an entrepreneurial mindset among students involved in the racing car program, according to Scott Wolter, Associate Professor and Chair of the Department of Engineering.
Nicholas Muller 24′ and Henry Echt 24′, students in Elon’s racing car program, collaborate on the electric racecar chassis design.
“You might conceptually understand car construction, but the true learning emerges during the design and build phases, where you deeply grasp the underlying principles,” Wolter elaborated. “This is a key advantage of FSAE competitions and our racing car program: students apply classroom knowledge in real-world scenarios. This experiential learning methodology is at the heart of the educational environment we cultivate for our students at Elon.”
Since its inception in 1981, FSAE competitions have challenged undergraduate and graduate teams to innovate by designing, building, and demonstrating compact, single-seat vehicles. Judging criteria extend beyond mere speed to include design innovation, acceleration control, efficiency, and endurance. Participation in FSAE and developing a strong racing car program is a hallmark of a top-tier engineering institution. Larger universities often boast teams with over 100 members, benefiting from decades of accumulated design expertise passed down through generations of students.
Under the leadership of Muller, Henry Echt ’24, and Jack O’Donnell ’25, Elon’s team comprises 18 students from diverse academic disciplines, guided by Engineering Lab Manager Matthew Banks. Elements of this inaugural car design have been integrated into the year-long Senior Projects in Elon Engineering Design (SPEED) course. Seniors in this course are focusing on the car’s subsystem design and construction – specifically the human-machine interface and ergonomics – as their capstone project, further embedding the racing car program into the curriculum.
Maggie Dion 26′, a member of Phoenix Racing, Elon’s racing car program, meticulously refines a component in the Clark Prototype Lab.
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 a late-night session in February, marking a significant milestone for the racing car program.
“I thrive on the daily challenges this project presents,” Echt shared. “The variety of discussions and problem-solving scenarios enriches my academic perspective across all my classes, enhancing my experience within the racing car program.”
Ben Trainum ’24, double majoring in engineering with a computing concentration and computer science, finds the advanced design aspects particularly stimulating. He has dedicated countless hours to designing the car’s rechargeable battery system, acquiring skills and a depth of expertise that classroom learning alone cannot provide. His involvement in the racing car program is proving invaluable.
“These kinds of complex tasks are typically assigned to graduate-level students. Through this team, I am independently learning and applying high-voltage battery pack design, CNC machining, manual machining, and gaining significantly deeper mechanical design experience,” Trainum explained.
Ben Trainum 24′, a key member of the racing car program at Elon University, fabricates a part in the Clark Prototype Lab.
Team members have actively built connections with industry experts and academic professionals at other institutions. They constructed the chassis during the spring and summer, benefiting from the expertise of the welding program at Alamance Community College. These collaborations are vital to the success of the racing car program.
Beyond prototyping, the team is focused on developing compelling pitches for potential sponsors and nurturing relationships with business partners. Having already raised over $24,000 of their $40,000 goal to be competition-ready by May, Phoenix Racing has secured an impressive portfolio of sponsors, including industry leaders like Sandvik Coromant, Bravo Team, AKG of America, Corvid Technologies, and ACI Automotive and Performance. This financial support is crucial for sustaining the racing car program.
Much work remains to be done before the car is competition-ready. The team needs to complete the bodywork, finalize the power packs and battery management system, complete the electrical system, and fabricate the suspension. These are critical steps for the racing car program.
However, the extensive hours, late nights, and weekends invested in the IQ’s machine shop are demonstrably advancing the project towards the June 2024 competition deadline. The dedication is palpable within the racing car program.
“For me, the most rewarding aspect is our team’s identity,” Echt reflected. “We are united by a common goal: to build this car, compete in Detroit, and demonstrate what a dedicated, lean team can achieve. This spirit defines our racing car program.”
Individuals interested in supporting or joining this exciting initiative are encouraged to contact Phoenix Racing at [email protected] and become part of Elon’s pioneering racing car program.
