Design and Fabrication of Car: A Comprehensive Approach by Undergraduate Engineers

This paper explains the step-by-step process followed to design and fabricate a low-cost, lightweight car using easily available materials and components. The main goal was to gain practical knowledge by applying engineering principles such as mechanics, thermodynamics, materials science, and manufacturing techniques. The design process began with sketching and CAD modeling, followed by the fabrication of a tubular frame chassis using mild steel. A 150cc Bajaj Pulsar engine was selected for its compact size and reliable performance, and a chain drive was used to transmit power to the rear wheels. The car’s body was made using umbrella cloth, chosen for its lightweight and flexible nature, which also helped reduce overall cost. Suspension, steering, and braking systems were custom-built and fitted as per design requirements. The entire assembly was carried out using basic tools in a college workshop setup. After fabrication, the vehicle was tested and found to perform efficiently under normal driving conditions. This paper discusses each stage of the project, along with the challenges faced during design and manufacturing, and the practical solutions adopted.