UF Solar Gators. Electrical Battery Pack Lead and Wiring Lead. Role ended summer 2025.
What I owned
Custom Altium PCBs: active-balancing hat board and BMS with over/under-current, voltage, and temperature protection.
C++ trip logic, checked on the installed pack.
Nearly every wire on Flare: crimp, solder, fuse, connector, Tesa. Layout changed mid-build; remaining high-current stock was limited.
Printed enclosures for starter switch, rear-camera screen, and dashboard. Helped assemble body, pack, and array.
Result
146 laps at the 2025 Formula Sun Grand Prix — Solar Gators’ best first-year result on a new car. The prior year I rewired the previous pack and raced 1,465.8 miles in the 2024 American Solar Challenge.
Solar Gators with Flare at FSGP 2025Crew around Flare with the canopy openCrew with Flare on the FSGP courseWalking Flare on the FSGP courseWorking on Flare in the FSGP paddockDriver in Flare in the FSGP paddockCockpit at FSGP 2025Steering and front suspension from the cockpit at FSGPFlare in the shop during assemblyCarbon body and pack bay during shop assemblyWetting carbon on the Flare bottom-body moldFlare bottom-body layupCarbon in the bottom-body moldFlare bottom-body layupPeel ply on the Flare bottom-body layupFlare bottom-body layupVacuum bag going over the bottom-body moldBrushing resin on the Flare bottom bodyTeam laying up the Flare bottom bodyTeam laying up the Flare bottom bodyVacuum bag on the Flare bottom-body moldTeam after Flare bottom-body layup #1, 2025Demolded Flare carbon bottom bodyFlare bottom body next to the red moldFlare bottom-body layup clipFlare bottom-body layup timelapseCustom BMS installed in the Flare packFlare battery pack in the boxFlare pack modules numbered in the boxFlare pack during assembly — busbars, contactors, and HV cableMotor controller, control boards, and Elmar MPPTs installedMitsuba motor controller and neighboring boards in the chassisWiring to Elmar MPPTs and control boards in the chassisDashboard board by Samuel Breslin — wiring and mounts are minePrinted dashboard, backup-camera, and starter-switch mounts — this combined layout was never used on the carCAD of the combined dashboard, backup-camera, and starter-switch mountsLater backup-camera mount, closer to the design that went on the carBackup-camera mount next to the rear shockBackup-camera screen on the later printed mountFitting the backup-camera screen to the later mountVCU — I did not design this board; harness is mineSteering-wheel board — I did not design this board; wiring is mineMotor controller and VCU harness on the benchElmar MPPTs and team boards on the bench — I did not design these boardsAmphenol SurLok on orange high-voltage cableSpool of orange high-voltage wireHarness cut to lengthCrimp tools used on the vehicle harnessWiring example — sleeved harness with Deutsch connectorsWiring example — Deutsch connectors and heat-shrinkUnreleased Flare pack-box CADImpound-box CAD — designed for Sunrider, also used with FlareFSGP 2025 clipFSGP 2025 clip
