Have you ever dreamed of building your own race car from scratch?
Not just a toy model or a simulator version, but a real, functional race car that can accelerate from 0 to 100 km/h in under four seconds?
For most of us, the idea sounds far-fetched—after all, designing and constructing a high-performance vehicle typically requires a hefty budget, top-tier engineering facilities, and years of experience.
But for a group of ambitious students from the University of Waikato, that dream has become a reality.
Meet Todd Carswell and Josh McIntyre, two mechanical engineering students who, along with their teammates in the Waikato Engineering Student Motorsport Organization (WESMO), have designed and built a race car that not only runs but competes on an international stage.
Their creation can reach speeds of 160 km/h, and the best part? They built it all using funds they raised themselves.
A Launchpad for Future Engineers
Formula SAE (FSAE) is an international competition that gives undergraduate students the opportunity to design, build, and race their own open-wheel race cars.
Organized by the Society of Automotive Engineers (SAE), the competition isn’t just about speed—it’s about innovation, cost-efficiency, and real-world problem-solving.
WESMO’s team is currently ranked 6th in Australasia and holds the 87th spot out of 600 university teams worldwide, a remarkable achievement given the financial and technical challenges they face.
In December, they will compete in Formula SAE Australasia, which will take place in Melbourne, Australia.
But how exactly do a group of students, without access to the deep pockets of Formula 1 teams, build a high-performance race car?
Building a Race Car on a Budget
One of the most impressive aspects of WESMO’s project is their ability to source materials and components without breaking the bank.
Unlike professional racing teams that operate with millions in funding, student teams must be resourceful, often securing sponsorships, repurposing parts, and finding cost-effective alternatives.
Todd and Josh explained that the car’s chassis, aerodynamics, and powertrain had to be designed from scratch using CAD (Computer-Aided Design) software before any physical work could begin.
They relied on university resources, crowdfunding, and sponsorship deals with local businesses to acquire the necessary materials.
Even with these financial limitations, the team’s car is packed with high-performance features.
It boasts a lightweight frame, a precision-tuned suspension system, and an optimized powertrain that allows for rapid acceleration.
Every component was carefully selected to balance performance, weight, and affordability.
Faster Isn’t Always Better
When we think of race cars, our minds often jump to speed as the ultimate factor.
However, one of the biggest surprises in the Formula SAE competition is that raw speed isn’t the primary goal.
Instead, teams are judged on a combination of factors, including design, cost efficiency, endurance, and overall engineering innovation.
Unlike Formula 1, where manufacturers push for extreme speeds, student-built race cars must strike a delicate balance between performance and reliability.
If a car is too fast but lacks control, it can fail in the endurance segment of the competition. If it’s too complex, maintenance and repairs become a nightmare during the races.
This is where smart engineering decisions make all the difference. Instead of chasing unrealistic top speeds, WESMO focused on optimizing their vehicle’s aerodynamics, fuel efficiency, and stability.
Their design choices ensure the car performs well not just in a straight line but across a variety of dynamic tests.
The Future of Race Car Engineering
The work done by student teams like WESMO isn’t just for competition—it reflects broader trends in the automotive industry.
As manufacturers move toward sustainable energy solutions and efficiency-focused designs, these students are gaining hands-on experience in the very technologies that will define the future of transportation.
From lightweight materials to advanced software simulations, the innovations being tested in student competitions often make their way into real-world automotive applications.
Formula SAE alumni frequently go on to work in motorsports, electric vehicle development, and aerospace engineering.
Josh and Todd are confident that the experience they’ve gained will set them up for exciting careers in the automotive sector.
Their ability to design under constraints, think critically, and problem-solve in high-pressure situations makes them highly sought-after candidates in the engineering world.
Why This Matters for Aspiring Engineers
If you’ve ever thought about pursuing engineering but worried that it might be too theoretical or unattainable, projects like Formula SAE prove that hands-on experience is alive and well in university programs.
Students aren’t just learning from textbooks—they’re applying their knowledge to real-world challenges, collaborating in teams, and building tangible products.
The University of Waikato offers a range of engineering programs that allow students to get involved in projects like WESMO.
Whether your passion lies in mechanical design, electrical systems, or software development, opportunities like this provide a stepping stone into a rapidly evolving industry.
Final Thoughts
We might not all be capable of designing a race car, but thanks to competitions like Formula SAE, the next generation of engineers is proving that innovation isn’t limited to high-budget factories and corporate labs.
It’s happening in university workshops, where students with a vision—and a whole lot of determination—are redefining what’s possible.
Good luck to the WESMO team in their upcoming competition! If you’re an aspiring engineer, maybe one day you’ll be the one building the next big breakthrough in motorsports.
Source: University of Waikato
