Critical Design Review Guidelines
Overall Goal
Close to final part-level design for every system
In-depth manufacturing plans including
Process steps
# of setups, jigging plans, layup process, etc
Machines used
Tooling specified if requires specialty tooling
Materials needed
Final validation and FEA
Updated between PDR and CDR
Rough Manufacturing Timeline
Presentation Content
Dynamics | Body | Electromechanical | Aeroshell |
|---|---|---|---|
Overall Load cases Factor of Safety considerations Manufacturing options | Overall | Overall | Overall |
Suspension Hardpoints Parameters (scrub radius, roll center height, KPI, caster, bump steer) CG Goals Shock selection Suspension Stiffness Ride height Roll gradient Ride frequency Validation Sensors (selection and what to do with data) Parameters (how will you measure parameters and adjust based on data) Pushrod design Size and material selection Control arm design Overall design Apex design Manufacturing considerations Failure modes and stress Packaging Front packaging Rear packaging Bellcranks Design and assembly Material selection Topology optimization (if applicable) FEA Simulation setup Simulation results Manufacturing timelines Highlight changes from PDR Any other information specific to your design that needs to be reviewed | Frame Targets and Metrics Weight goal Torsional rigidity goal Design Overview Tube selection Material selection (including filler for welding) Packaging and System Integration Packaging layout Dynamics integration Aeroshell integration Emech integration Ergo integration Simulations Torsional sims (setup and results) Impact sims (setup and results) Manufacturing considerations Jigging plan Hardpoints Frame tubes Other tabs Jig specifications (architecture, material, size, fasteners) Tolerances (including stacked tolerances) Highlight changes from PDR Any other information specific to your design that needs to be reviewed | Battery Battery layout Components Material selection Manufacturing plan | Aerodynamics Design philosophy/process Shell design Shell configuration (canopy, top/middle, bottom, aero covers) Cl and Cd goals CFD analysis Setup Results |
Unsprung Assembly overview Component overview (material, manufacturability, areas of improvement) Upright (including pickups and shims) Hubs Axle/spindle Brake rotor Component selection Caliper selection Bearing selection Fastener selection (nuts, retaining rings, etc.) Hand calculations FEA Simulation setup Simulation results Fatigue analysis Hubs Axle/spindle Highlight changes from PDR Any other information specific to your design that needs to be reviewed | Enclosures Enclosure Mounting Locations Material selection Hardware selection Simulations Setup Results Manufacturing plan Waterproofing Plan | ||
Steering Packaging Upper steering Lower steering Component selection Steering rack U-joints/gears Support bearings Steering geometry Ackermann Parameters Steering effort Scrub radius Highlight changes from PDR Any other information specific to your design that needs to be reviewed | Ergo Brakes system Overall layout Master cylinder selection Balance bar selection Hand brake selection Driver Anthropometrics/Positioning Elbow room Hip room Head room Pedal box distance Steering wheel angle and distance from driver Pedal box Design overview Mounting and hardware FEA simulation (setup and results) Hand calcs Steering wheel Design overview Manufacturing considerations Seat, headrest, and harness Positioning Material selection Mounting Manufacturing considerations Belly pan Material selection Manufacturing considerations Ballast box Material selection Manufacturing considerations Highlight changes from PDR Any other information specific to your design that needs to be reviewed | Cooling Cooling Strategy Selected Type of cooling system Layout/packaging Routing Scheme Material/component selection Battery Thermal Testing Results | Composites Material selection For each section of the shell For any hinging mechanism/fastening mechanism Epoxy, mold release, etc. Manufacturing plan Mold Layups Mold release Etc. Testing Setups Results Specs of components being tested |
Wire Harnessing Preliminary wiring diagram Component selection Hardware selection |