October 2025 Newsletter

Organization Updates:

Longhorn Racing has been incredibly busy to kick off the fall semester! From recruitment to Formula 1, our teams have been busy networking and maintaining our facilities to ensure our engineers can deliver the best cars for the 2025-2026 competition season.

Recruitment

Longhorn Racing is happy to welcome 153 new members this year after an incredibly competitive recruitment cycle. LHR saw over 2,000 applications for all three teams coming from a variety of majors across UT. Combustion accepted 47 new members, Electric 60, and Solar 46. Our new members have worked incredibly hard so far this year, and we’re excited for the next step.

Formula 1 & Events

Our members had several opportunities this year to meet and talk to professionals in F1, including trackside engineers, heads of marketing, and even development drivers. Akkodis, a partner of the Mercedes-AMG Petronas F1 Team, hosted a panel featuring five Mercedes staff members for LHR on campus. Visa Cash App Racing Bulls (VCARB) partner Yugo reached out to LHR to collaborate and host a campus-wide raffle for a garage tour alongside a panel with VCARB’s Head of Marketing, Fabian Wrabetz. Arm also collaborated with Longhorn Racing and the Aston Martin F1 Team to arrange an opportunity for our engineers to meet and interact with Aston Martin staff and drivers at Ann Richards’ School. Through these events, seven members were invited to garage tours, 3 received paddock passes, and Driven to Care provided 13 grandstand tickets to watch the Friday sessions. Longhorn Racing is incredibly grateful for these events and thanks each of these organizations for providing these opportunities!

Networking & Facilities

Our Solar and Electric teams spent time attending conferences and events hosted by other organizations. The Solar Team participated in the Austin Regional Manufacturers Association (ARMA) to network with potential partners across the Austin area. The Electric team also hosted an event with Base Power and sent five members for a design review with Bosch in Detroit.

Our facilities team has been working diligently to clean up and establish new standards as we prepare for manufacturing. This year’s Hornraiser, dedicated to safety, exceeded our goal of $5,000 and will support efforts to ensure our engineers work in clean, safe spaces.

COMBUSTION

Team-Wide Updates:

The Longhorn Racing Combustion team just finished up our Preliminary Design Reviews for our systems, during which members of the team presented the progress on their system's designs to alumni and industry professionals and are now working to incorporate this feedback into their parts before their Critical Design Reviews in the coming weeks! For a couple of system specific updates, the Powertrain system is hard at work getting the new engine dyno system set up and running, and the Body system is finalizing the design and simulations of our frame before we send it out for manufacturing. Finally, we are hitting the track with drivedays starting up again, as we collect valuable data for design validation and seat time for our new class of drivers! This work would not be possible without the amazing support of our partners, friends, and family, and we hope to show you more of the impressive work our team puts out!

System Updates

The Composites team has made significant progress, recently completing front wing simulations in ACP using carbon fiber models and finalizing the initial CAD for the front wing mold. They’ve also developed preliminary CAD for the undertray, simulated the headrest, and are currently working on a new six-bar setup for the rear wing mounting. The team has been documenting headrest simulations, refining ply counts and structural setups, and collaborating with Aerodynamics on wind tunnel testing plans. In addition, they’re improving manufacturing processes: developing better bonding methods between carbon fiber and aluminum components, streamlining workflows with Python automation, and ensuring accurate CAD weights. With all members now proficient in ACP and preliminary front wing simulations complete, the team is ahead of schedule and focused on validation and readiness for CDR.

The Aerodynamics team’s biggest achievement this year has been replicating last year’s front wing performance while significantly reducing manufacturing complexity. Since May, they’ve completed over 50 simulations emphasizing efficiency over complexity, with new members quickly making meaningful contributions through a streamlined onboarding process. The team is also developing an engine cover, conducting flow visualization and pressure mapping on the car, and researching radiator mass flow rates as part of their testing projects. Looking ahead to CDR, they’re excited to integrate more automation into their workflow with help from their Computer Science members and are aiming to finalize the aerodynamics package by the end of the year! 

Body’s subsystems have been hard at work after a successful PDR, with the Frame team continuing to iterate on design, prioritizing weight and torsional rigidity, while Ergonomics has made strong progress in all their projects. In collaboration with Dynamics, they’ve received load cases for hardpoints and are now optimizing tab design. The Frame team is working with the steering geometry and adjusting the cockpit and front roll hoop sizing, ensuring proper fit and performance. Meanwhile, the Ergonomics team is simulating forces on the pedal box, and new members are contributing to the development of the clutch and steering wheel systems. The overall team is looking forward to CDR and getting closure on their designs. 

Dynamics’s most significant achievement is getting their Truss Solver program fully operational, and they have also been finalizing their new set of hard points. These updates have enabled more realistic simulations and supported the Body team in advancing their next iteration of the frame. The team has also been adjusting their key suspension parameters, including Camber Gain, Ride Frequencies, Motion Ratios, and Steering & Ackermann, to optimize vehicle performance. Following a successful and productive PDR, where new members presented their projects and the team received positive feedback on their suspension packages and part designs, and are now preparing to finalize the geometry for the frame and moving towards finalizing part-level design.

The Electronics team’s main focus and achievement this year is revamping the Smart PDM (Power Distribution Module), which presented some performance challenges last season. The new design prioritizes reliability and ease of use, reducing the need for other teams to troubleshoot electrical issues. Additionally, the team is developing a custom display, remote tuning software, and a customized ECU to manage engine control functions, such as spark timing and fuel injection.

The Powertrain team has been focused on reducing mass and improving engine power through intensive heat rejection calculations and high compression pistons. For Drivetrain, they’ve changed to new differential, titanium components, reducing rotating mass, and improving both power-to-weight ratio and efficiency. Powertrain has also introduced a new fuel type for increased engine output and is developing a custom oil pan and hard lining to enhance cooling abilities. With the stop-work order lifted, the team’s largest focus has been getting the engine dyno running to begin testing and tuning. Looking ahead, they’re excited to watch all components come together and see their hard work translate into performance gains this year.

The Simulation & Validation system has worked successfully on updating the tire and MMM models for the car and is now working with Dynamics to help set suspension parameters with the kinematics model. They have made strong progress on their Julia Laptime Simulation, transitioning from a steady-state model to a transient model and developing a differential model to support it. Looking ahead, SimVal is looking forward to fully developing the Julia Laptime Simulation to enhance overall vehicle performance. 

ELECTRIC

Team Wide Updates

The Electric team is kicking off the new school year, building upon the innovative developments from the previous year. As their new leadership team plans the high-level goals for the next car, our design systems are eagerly jumping into R&D and validation work informed by past vehicles. They’d like to thank their outgoing leadership and graduating members for their incredible contributions, and they’re especially grateful to all of their families, friends, faculty advisors, and partners for their continued support. We’re excited for what's ahead!

System Updates

Aerodynamics has been advancing high-fidelity simulations through the Texas Advanced Computing Center. The team has refined downforce and drag performance, completed mold production for major components, and is preparing for a full R1 aerodynamic package freeze on November ninth.

Body has finalized the frame design for this year, and is currently manufacturing welding fixtures for when frame welding begins. Other designs such as steering wheel, dash, headrest, and closeout panels are in a good design state for manufacturing as well. The team is looking forward to welding our frame in an effective manner in the coming weeks.

Dynamics has been improving design efficiency and tuneability, aiming to maximize performance gains through track time. This year's design includes dual anti-roll bars, a longitudinally adjustable pedal box, and straight steering column. They are actively working to freeze designs and begin manufacturing on November ninth in order to have a rolling chassis by February fourth.

Electronics has achieved major milestones this month. Rev A boards have arrived and are undergoing validation. Harness design is sixty percent complete, powered by the integration of RapidHarness software. The system has also implemented USB-C debugging, flexible PCBs, and a 5G telemetry interface to improve data collection and reliability. Firmware development and enclosure testing are the next steps as the team prepares for full-vehicle integration.

Powertrain is focused on improving energy efficiency, safety, and modularity. Nickel fuse testing is underway, and fan placement has been optimized to strengthen thermal management. Drivetrain simulations and updated CAD timelines are driving collaboration across systems. The battery team is finalizing new mounting configurations and thermal routing, working with UT battery-testing labs to validate the design before the Electrical Systems Form deadline.

Trackside Engineering has introduced a new pre-drive-day procedure to improve testing efficiency. The first round of driver selections has been completed, and the team is now finalizing telemetry dashboards to deliver live performance data during shakedowns and tuning sessions

Vehicle Modeling has refined the FMU and co-simulation frameworks that allow engineers to connect real-time telemetry with predictive simulations. This work enhances design accuracy and reduces testing time, helping the team identify performance improvements before physical trials.

Corporate Relations continue to strengthen its foundation through key partnerships with Tesla, Bosch, SendCutSend, and Argio Roofing. Public Relations have expanded the team’s visibility through social media campaigns, subsystem highlights, and short videos showcasing technical progress and team culture. Treasury has improved purchasing and tracking for greater transparency and efficiency, while Sustainability has secured grants for new equipment and is exploring greener materials for manufacturing.

SOLAR

Team Wide Updates

The Solar team started off the fall build season enthusiastic, with the goal of achieving powered run by May and completing all scrutineering tests before heading to competition in the summer. The mechanical teams are working on CAD integration challenges and ordering key materials, while the electrical side has been soldering and assembling boards. The team has been able to restore their 2024-2025 competition car, Daybreak, back to driving condition after troubleshooting efforts with the dash and electrical enclosures. Solar is looking forward to the next year, as we enter the manufacturing cycle of the 2-year build cycle and thanks everyone for their continued support.

System Updates

The Aerodynamics System is finalizing their mounting mechanisms, including the tilting mechanism and the canopy hinge. Once that is complete, they will begin designing the canopy and wheel covers. Optimizing these components will allow the car to move seamlessly with the wind. The aerodynamics team has also started initial research into making an aerodynamic fin that will allow the car to produce thrust.

The Body System has successfully integrated a hall effect sensor onto the brake and accelerator pedals, increasing data collection accuracy. In addition, there has been a mass collection of driver data in order to select top performers for the circuit. Currently, we're finalizing our machining and outlining plan for the welding jig to make sure the frame is as accurate to CAD as possible. Furthermore, we are assisting the Composites system in research and design of a complete composite frame for the 2028 car.

The Dynamics System is currently finalizing designs for the rear trailing arm and front uprights on NextGen and is on track to begin manufacturing by the end of the month. They recently towed Daybreak around Pickle Research Campus and gathered valuable load and cycling data which will be used for fatigue analysis. Looking ahead, they aim to learn more from on track testing and gather tire data for the development of a custom driver in loop simulation.

The Composite System has spent time optimizing the aeroshell and bulkheads to maximize structural strength by running FEA simulations. They are also finishing up designing the first iterations for the composite frame and are beginning to create simulation setups, and have passed 2 out of five load cases. Progress is also being made on research for joints and inserts for the composite frame, along with composite stiffness calculations.

The Power Generation System has been making strides to get the first revisions of the PCBs sent out for manufacturing: "Blackbody", the irradiance and temperature sensor board, "Heliosphere", the control board for cell testing and characterization, and our MPPT boost converter, a DC-DC converter to be part of the MPPT. Furthermore, we redesigned our simulation program, "Aurora", to act as our software simulation application for our array. For the next month, they will be working on soldering, testing, and writing firmware for all of our boards and sending out our array layout design to start laminating our test modules.

The Power Systems System has finalized designs for the first revision of circuit boards for this year’s car. We are currently working on assembling and validating the electronics for the low voltage power distribution and battery management system. Additionally, the system on module power architecture has been verified and is ready to use on several boards throughout the car. Over the next few weeks, we’re looking forward to finalizing our wire harness design and starting benchtop integration with the other electrical systems.

The Powertrain System is currently finalizing various enclosures such as the dashboard and power distribution and will soon be moving into manufacturing. The main and supplemental batteries have been reviewed and are ready to manufacture, pending getting a composite space. All thermal designs are undergoing development and validation.

The Vehicle Controls and Telemetry (VCAT) System is nearing the testing phases for the initial revision of controls leader and raspberry pi display board. The telemetry subsystem is developing an initial revision for the wheels board and the air board, which each have exciting new sensors for mechanical systems to use. Our visualization software Photon also now supports encoded video playback. We are working on finalizing the initial board designs done, getting it ordered and tested, as well as expanding the functionality of Photon to include 3D car rendering, more robust networking, and digital signal processing.

The Operations team has been working to streamline the purchasing process and ensure that all money inflows and outflows are detailed and tracked accurately. The CR team has been working to get system-specific materials along with monetary partnerships. We are also underway in creating merchandise for the Solar team.