The car
The NUS Formula SAE R26e is our fully electric formula car for FSAE Michigan 2026. It weighs 198 kg, sits in a carbon fibre monocoque, and the aero makes over 1,330 N of downforce at 80 km/h.
Power comes from a custom 6.88 kWh pack — up to 137 kW peak — into an Emrax 228 (liquid-cooled) through a BorgWarner Cascadia Motion CM200DX. Rear-wheel drive, 220 Nm peak torque.
LV electrics and PCBs
I designed the low-voltage system: STM32 controllers, power/IO, 12 V DC-DC converters, and the LV power budget. Boards are laid out to IPC-2221A Class 3 so they survive vibration and heat on an endurance car.
I designed 4 custom PCBs and put 2 on the car — the STM32F4 dashboard (buttons, knobs, LEDs, CAN) and a BSPD diagnostic board. Dedicated CAN routing, proper creepage, test points, connectors. I assembled and bench-tested them before they went on the car.
Dashboard
The dashboard runs FreeRTOS on an STM32F4. Drivers can change current limits and regen from the wheel. Updates come over CAN so the display doesn't lag.
Telemetry
We stream 15 CAN IDs to AWS over a SIM7600G. About 10 updates/sec, usually under 100 ms. That feeds a Next.js app with live plots, temps, and a rough energy estimate so we can pace endurance.
CAN and logging
The car's 1 Mbps CAN bus hits 39 sensors (aero, suspension, brakes). I made a small web CAN/DBC configurator so we can edit and export the message map across all three buses. I spent a while cleaning up bus traffic so the motor actually gets commands on time. We log at 100 Hz and look at it in MoTeC i2 for braking points and lines.
Harnesses
I built most of the LV harnessing — waterproof, meant for race vibration, heat, and rain. Also packaged the BSPD, sensors, and dashboard with the other teams.
ECU and regen
I wrote firmware on the MoTeC M150 for launch control and CAN out. The thing I'm happiest with is the active brake regen: when you press the pedal it blocks rear brake fluid and uses the motor instead. We got about 46% of the kinetic energy back, with peak charge around -98.5 A.