Project Overview:

In this project, our team was tasked with developing CAD models for an electric vehicle drivetrain system — specifically the E-Motor housing and E-Axle assembly. The challenge was to deliver compact yet structurally sound designs optimized for manufacturing and thermal performance.

Key Challenges

- Space constraints within the EV chassis

- Integration with existing gearbox architecture

- Thermal flow management for motor cooling

- Lightweighting without compromising strength

Our Engineering Approach:

- Created detailed 3D CAD models using SolidWorks

- Performed iterative modeling and section-based validation

- Applied DFM techniques for casting and CNC compatibility

- Incorporated tolerance stack-up analysis for tight component fits

- Delivered fully annotated 2D drawings for prototyping

Results & Outcomes:

- Achieved 15% weight reduction through optimized wall geometry

- Reduced development time by 30% via modular CAD library reuse

- Successful thermal simulation handoff to CAE team Accelerated prototype-to-manufacture turnaround