Sam Bahrami
Chassis Lead @Utfr - University Of Toronto Formula Racing
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WORK HISTORY
Chassis Lead @Utfr - University Of Toronto Formula Racing
Toronto, ON, CA
Owned the chassis structural architecture and load-path design for a Formula SAE electric car, defining tube layout, node geometry, triangulation strategy, and joint design to meet rules and safety requirements.Translated suspension/drivetrain and impact load cases into frame requirements using Ansys FEA, MATLAB, and hand calculations, iterating tube sizing and wall thickness to minimize mass while maintaining stiffness.Reduced chassis mass by 20% and cost by 43% through simulation-driven optimization and design-for-manufacturing changes (tube selection, joint simplification, and build-time reduction) while preserving structural performance.Designed the full manufacturing system: weld fixtures, cut lists, build sequence, and composite panel interfaces to ensure dimensional accuracy, repeatability, and robust load transfer.Fabricated and assembled the complete chassis, including TIG welding, composite bonding, and structural integration into the full vehicle platform.
EDUCATION
University of Toronto
Bachelor of Applied Science - BASc, Mechanical Engineering
ABOUT SAM BAHRAMI
4th year Mechanical Engineering student at the University of Toronto specializing in vehicle systems, product design, and high-performance mechanisms. Experienced in CAD modeling, manufacturing, and prototyping.Currently serving as Chassis Lead at U of T Formula SAE Racing (UTFR), leading chassis design, validation, and manufacturing for the UT26 electric Formula SAE vehicle while coordinating integration across powertrain, suspension, aero, and accumulator systems.
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