Lucas Goellner

Mechanical Engineering and Design.

View CAD Work → Get In Touch

Dearborn Electric Racing · FSAE Michigan 2025

00 / ABOUTB.S. Mech Eng · UMich '28

Mechanical Engineering Student · CAD Design Focus

UMich engineer. Competition hardware. First principles analysis.

DegreeB.S.E Mech Eng

SchoolUniversity of Michigan

StartedSep 2024

GradMay 2028

StatusSeeking Intern · S'27

CURRENT

Chassis Engineer on the Michigan Mars Rover Team, designed the differential bar and chassis body in Siemens NX.

Brake System Team Lead at Dearborn Electric Racing, led the FSAE EV pedal box through first principles analysis, mechanical design, FEA validation, and in-house manufacturing on a $2,000 budget.

01 / PROJECTS Featured Work

FSAE EV · 2024–2025

Brake System & Pedal Box

32 parts · FoS 2.9 · $2K · Competition Verified

MRover · 2025–2026

Differential Bar & Chassis

Siemens NX · Carbon & Metal · In-House

03 / CAPABILITIESSoftware · Methods · Tools

SolidWorks Parts · Assemblies · Drawings

Siemens NX Chassis · Differential · MRover

SW Simulation Static FEA · FoS Analysis

AutoCAD 2D Drafting · Layouts

Mill & Lathe In-House Machining · Tolerancing

3D Printing Sensor Mounts · Prototypes

Laser Cutting Sheet Stock · Templates

Carbon & Metal Joining Composite Layup · Welding Prep

04 / CONTACTUMich · Ann Arbor

Mechanical Design Internship · Summer 2027

Open for internships.

Personalgoellnerlucas@gmail.com

Universitygoellner@umich.edu

LinkedIn/lucasgoellnerpf

StatusOpen · Summer 2027

/ EMAIL · PERSONAL

goellnerlucas@gmail.com

Latest - MRover & FSAE

Team Projects

FSAE · MRover

01 / FEATUREDFSAE EV · 2024 -2025

Dearborn Electric Racing · Brake System Team Lead

Brake System Design. Pedal Box Assembly.

SystemPedal Box

SoftwareSolidWorks

Components32 Parts

Budget$2,000

● PEDAL_BOX_V9 · 3D

/ 00 - OVERVIEW

32-part assembly. Competition-validated. Zero failures.

Owned the brake architecture, pedal box design, and sensor integration on Dearborn Electric Racing's FSAE EV. The new layout gave the driver 80mm of additional leg room and integrated cleanly with the steel space frame.

2.9factor of safety

32parts

7pedal iterations

$2Kbudget

/ A1 - BRAKE PEDAL

7 iterations. 2,000 N load. 2.9 factor of safety.

Modeled in SolidWorks and validated through SolidWorks Simulation against the FSAE-mandated 2,000 N load. The final pedal endured peak braking force with a 2.9 factor of safety. Reoriented the master cylinders during the redesign to free up driver leg room. Designed with simple machining in mind so it could be fabricated in-house.

/ A2 - ACCELERATOR

Accelerator pedal, return spring, hard stop, driver-adjustable extensions.

Mirrors the brake pedal geometry on the right side with a return gas spring and hard stop to bound travel. 3D-printed pedal extensions accommodated different driver heights without re-machining the main arms, useful when manufacturing time was tight.

/ B1 - MASTER CYLINDERS

Dual master cylinders, custom mounts, $2,000 total budget.

Two master cylinders, one for each brake circuit, mounted below the pedal box on weld-on steel tabs that tied into the steel space frame. Refurbished rotors and sourced calipers (AP Racing 4227 front, Magura rear) kept the entire brake system within the $2,000 budget.

/ B2 - BALANCE BAR

Adjustable front/rear brake bias, FSAE T.3.1.3 compliant.

The balance bar is a pivoting link between the brake pedal and the two master cylinders. Adjusts brake bias front-to-rear without re-plumbing the system, critical for tuning across track conditions and rule-required by FSAE T.3.1.3 (two independent hydraulic circuits).

/ C1 - APPS SENSOR MOUNT

APPS and brake pressure mounts, 3D-printed, tuned to pedal pivot axis.

Custom mounts for the Accelerator Pedal Position Sensor and brake pressure sensors, designed in coordination with the electrical and software teams. 3D-printed for fast iteration and tight geometry around the pedal pivot axis.

Download CAD Files (.zip) →

Renders & FEA

1 / 5

01PEDAL BOX · FRONT VIEW

/ Downloads

↓

Brake System CDR

Dearborn Electric Racing · FSAE 2025 · .pptx · 3.6 MB

Media DER Build Photos →

Dearborn Electric Racing · FSAE Michigan 2025 · Photos Tab

02 / FEATUREDMRover · 2025–2026

Michigan Mars Rover Team · Chassis Engineer

Differential Bar Redesign. Chassis Body Engineering.

SystemChassis

SoftwareSiemens NX

MaterialsCarbon · Metal

ManufacturingIn-House

StatusCompleted

● DIFF_BAR_ASSM · 3D

/ 00 - THE ROLE

Differential bar, equalizing six-wheel suspension loads.

As Chassis Engineer on the Michigan Mars Rover Team, I helped design and build the differential bar and chassis body components in Siemens NX. The differential bar is the equalizer in a rocker-bogie suspension. When one side climbs an obstacle, the bar transfers that motion to the opposite rocker so all six wheels stay loaded.

NXSiemens NX

6wheels equalized

URCcompetition

/ D1 - DIFFERENTIAL BAR

Reduced clearance. Tighter fits. Less lost motion.

The bar itself is a pivoting beam across the chassis spine, with each end linked to one rocker arm. The current design pass focuses on tighter machining tolerances and a redesigned joint at each end, both targeted at reducing lost motion through the equalizer.

/ D2 - CENTER PIVOT

Center pivot, bending and shear under full suspension load.

The center pivot is the only attachment point between the bar and the chassis body. It handles bending and shear under full suspension load while staying low-friction. Bearing and shaft sizing are tuned for both load capacity and smooth motion.

/ E1 - JOINTS

Rod end selection and tie-rod geometry, eliminating lost motion at the joints.

Each end of the bar connects to its rocker through ball joint rod ends. Simplifying the joint geometry from the previous year's design brings tolerances into a range that's achievable in-house.

/ F1 - CHASSIS BODY

Chassis body, cross-team integration, carbon fiber and metal.

Beyond the differential bar, I helped design chassis body components that integrate with electrical and software subsystems.

/ G1 - IN-HOUSE BUILD

In-house fabrication, CNC mill, traditional mill, lathe, waterjet.

Manufacturing parts in-house using the team's CNC mill, traditional mill, lathe, and waterjet. Designing in NX with in-house fabrication tightens the feedback loop on tolerance choices.

Media MRover Build Photos →

Michigan Mars Rover Team · URC 2026 · Photos Tab

03 / MODELS Wireframe 3D · Drag to Rotate

SolidWorks · FSAE EV · MRover

Explore the CAD.

Pedal BoxGLB · 32 Parts

Diff BarSTL → GLB

InteractDrag · Zoom · Auto-Rotate

/ 01 -PEDAL BOX V9 -FSAE EV

● PEDAL_BOX_V9 · 32 PARTS

HOST ON GITHUB PAGES
TO ENABLE 3D VIEWER

Download GLB → Download SolidWorks (.zip) →

/ 02 -DIFFERENTIAL BAR -MROVER URC 2026

● DIFF BAR ASSEMBLY · URC 2026

HOST ON GITHUB PAGES
TO ENABLE 3D VIEWER

Download GLB →

Class Projects

University of Michigan

04 / FEATUREDMECH ENG 250 · 2025

University of Michigan · Manufacturing & Design · The Servo Sheriffs

Robot Manufacturing Project. Hat Clamp.

CourseMECH ENG 250

SoftwareSolidWorks · FEA

Mfg.CNC Mill · 3D Print · Waterjet

Grab Rate90%

Hook Rate90%

Result3rd / 14 Teams

● CLAMP V6 · 3D-PRINTED END EFFECTOR · MECH ENG 250

/ 01 - THE CLAW

Clamp V6. My subsystem. 3D-printed, iterated to a 90% grab rate.

The end effector was my responsibility on the team. I designed 2 claw concepts and one of my teammates designed one as well, then tested them head-to-head in an empirical test. The final geometry balanced inward grip force with clean release on the hook post, hitting 90% hat grab success and 90% hook placement in testing. The winning design was then iterated until this final design was used in the competition.

90%grab rate

90%hook rate

V6final rev

/ 02 - THE ROBOT

2-wheel drive, lead screw lift, 3D-printed claw. Built in one semester.

The Servo Sheriffs built a remote-controlled robot in a single semester for MECH ENG 250. The drivetrain uses two independently driven wheels for full 2D mobility. A lead screw actuator raises and lowers the claw vertically, with bearing blocks and a guide rail keeping the carriage aligned under load. SolidWorks and hand-written FEA were used throughout.

2wheel drive

Leadscrew lift

1semester

/ 03 - COMPETITION

3rd place. Two hats hooked on competition day.

On competition day, the Servo Sheriffs placed 3rd out of 14 teams in the full MECH ENG 250 class. The robot successfully hooked two hats, a result of the claw geometry holding up under real game conditions.

3rdplace

2hats hooked

T22Team 22

Media Team 22 Presentation Video →

MECH ENG 250 · Servo Sheriffs · Media Tab

04.5 / BUILD Servo Sheriffs · Competition Photos

MECH ENG 250 · Team 22 · 3rd / 14 Teams