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Marc-Antoine BeaudoinDesign Portfolio

This portfolio presents a selection of seven design projects completed during my engineering studies at Université de Sherbrooke and University of Toronto.

Design projects that took place in private companies were excluded for reasons of confidentiality.

Written on December 4th, 2016

Adapted from: www.mabeaudoin.com

Design of Vehicles

Electric Vehicle – Capstone project 2

Two-Speed Gearbox – Baja SAE 7

Design in Research

Combustion Testing – Sherbrooke 9

Gas Turbine Prototype – Sherbrooke 11

Vibration Testing – Toronto 12

Design in Education

Water Rocket – Sherbrooke 13

Water Rocket MDO – Toronto 14

Beyond - Capstone projectHigh efficiency electric vehicle

Beyond is a multidisciplinary project carried on during my final two years at Université de Sherbrooke. The team and I developed a very efficient electric vehicle. We won the Shell Eco Marathon Americas 2016 in the Battery Electric Prototype category and we were also given the Vehicle Design Award.

The goal of the competition is to complete a given number of lap, with a minimal velocity of 24 km/h, while consuming the least amount of energy possible. Each run lasts about 20 minutes. The teams have up to 6 trials, and the best run is taken for the final score. We achieved 731 km/kWh, which nearly doubles the score of team in second place.

Marc-Antoine Beaudoin – Design Portfolio 2

Key Points

+ I was the design coordinator for the two year development process

+ I developed a dynamic model to simulate the car’s on-track performance

+ We won the Shell Eco Marathon Americas 2016 and the Design Award


During the two year development period, I was the design coordinator, managing the work of the mechanical and electrical teams to ensure a coherent and performant design. The main design tasks for the mechanical team were the carbon fiber monocoque (optimized with respect to aerodynamic drag and weight), the transmission, steering system, wheel support, and the wheels themselves. The main design tasks for the electrical team were the motor controller and the electric motor.

Being the design coordinator was a challenging task because of the numerous interdependences between the systems. The vehicle had to be optimized as a whole, which required a lot of communication. Moreover, the space inside the vehicle was very limited, which also had to be managed carefully.



I developed a Matlab code to simulate the car's on-track performances. The simulator included a 6 DOF, 3 wheel model of the car coupled with a tyre model including slip angles to calculate the rolling resistance while cornering. The aerodynamic drag of the body and wheels was also considered, along with the bearing and clutch friction forces. The losses in the electric drive, electric motor and gears were included as well.

With the simulator, we could determine where were the most significant energy losses and what were the most sensitive design variables. We then focussed our design efforts at the right place. Additionally, we could answer design trade-off. For instance, we could tolerate an increase of 0.86 kg in the electric motor for every additional 1% in efficiency. We also decided to incline the wheels with 8° of camber to reduce the frontal area. The increase in rolling resistance was compensated by an even greater reduction in aerodynamic drag. The simulator also enabled us to establish a race strategy. We figured out that the kinetic energy stored in the vehicle at the end of the race was significant. It was better to do the first few laps with a slightly higher average velocity and to decelerate during the last lap to finish with less stored energy. We also determined where were the strategic places to accelerate around the track.

I also took part in the detailed design of several parts, including the wheels, spur gears, and other drivetrain components.


Two-Speed GearboxBaja SAE

I was part of the Baja SAE team during my first two years at Université de Sherbrooke. This experience ignited my passion for engineering design. During the first year, I designed the engine cover and the gas tank container. I became the team’s design coordinator during the second year and also designed a two-speed gearbox. It was mostly developed during evenings and weekends while I was concurrently doing an internship.

After the product architecture and the shifting mechanism were conceptualized, the gears were designed with a software called KISSsoft. Then the standards components were chosen and finally, the detailed design was finished in SolidWorks. It took about 300+ hours to complete the project. The parts were sent to many sponsors, and assembled just in time for the first competition.


Key Points

+ I was the team's design coordinator

+ I designed a two-speed gearbox during my 2nd year of engineering studies

Two-Speed GearboxBaja SAE


Combustion Test BenchesCAMUS Research Laboratory

I did two internships in the CAMUS Research Lab in Université de Sherbrooke. I was part of a team whose goal was to develop a totally reinvented gas turbine. My task was to investigate if we could use the effect of high g-field on combustion to enhance the burner's performances. The approach to the problem was essentially experimental. This means I had to design many combustion test benches.

The design approach at CAMUS is highly iterative, and design reviews are extensively used to ensure quality. As a result, my designs were continuously challenged by the professors and other team members, which presents a great opportunity for learning. I had to make sure the observations would not be altered by an undesired phenomenon, that we would obtain a sufficient acceleration level, and that the test bench simply wouldn't melt. I learned CNC machining and manufactured some of the parts I designed. Moreover, it was a great opportunity to extend and apply my knowledge of fluid mechanics, thermodynamics, combustion, and heat transfer.

I also developed a methodology to ignite the mixture and control the air and fuel mass flow. I used analog mass flow controllers and a program I designed in LabVIEW. I had to establish a good relationship with the university personnel to obtain the permission for the risky experiments.

The spreadsheet I built during the design process, along with the research paper I published from the test results, can be downloaded from my personal website: www.mabeaudoin.com


Key points

+ Many test benches were developed for the combustion of hydrogen, methane, and propane.

+ I used a Schlierenimaging technique and a high speed camera to observe the flame front oscillations.

Combustion Test BenchesCAMUS Research Laboratory


Gas Turbine PrototypeCAMUS Research Laboratory

During my internships at CAMUS, my team and I developed a gas turbine prototype. I was responsible for the design of the combustion chamber. The idea was to use the effect of g-field on combustion, hence the channels’ curvature. I had to integrate many sensors to the design as it was a proof of concept prototype.

I had design the combustor with respect to the turbine’s requirement. I used the equations of 1D compressible flows to calculate the fluid properties across the chamber. I also used the equations of Rayleigh flows for the section where heat is added by the combustion of reactants.


Key points

+ The combustion chamber was part of a gas turbine prototype.

+ The fluid properties were solved using 1D compressible flow and Rayleigh flow equations.

Vibration TestingARL-MLS – University of Toronto

The subject of my master’s is the non-linear dynamic analysis of bolted flange connections for aero-engine casings. More precisely, I want to develop an analytical model for the prediction of the vibration response of a bolted flange. I also want to validate the model experimentally. For this purpose, I needed to design an experimental apparatus. The flange of interest is located between the orange and blue parts. The orange part has two possible mounting sides, i.e. with and without a spigot connection. This feature enables to isolate the effect of the spigot on the vibration response. A slip table is designed to transmit the harmonic motion from the electromechanical shaker to the structure.


The main challenge was to design an apparatus that is stiff enough so that the flexibility of the table and its connection can be neglected, but also light enough so that the level of excitation is sufficient to excite the flange nonlinearities, given the shaker’s limitations. Moreover, the rollers had to be sized so that they do not begin to rattle when the structure hits resonance. Nonlinear dynamic analyses with ANSYS were performed to answer those design questions.

Key Points

+ The experimental set-up will be used to validate a nonlinear dynamic model.

+ This is a very low cost alternative to commercial slip tables

Water RocketCAMUS Research Laboratory

My Professor Jean-Sébastien Plante wanted to teach his children's kindergarten class a little bit of science. He asked his students at CAMUS to design a water rocket and a launch pad, which we did with great pleasure.

I decided to model the fluid mechanics of the propulsion system to determine the optimal quantity of water to put into the rocket. Thrust was calculated in 3 phases:

1) The water is expulsed and the air expands following an assumed isentropic process

2) The air is expulsed with a chocked flow at the bottle neck

3) The air is expulsed with a non-chocked compressible flow


We designed 3 rockets and we asked the kids to guess which would go the highest. One of the rockets was a double sized version with two bottles glued together. Another one had a nose cone to reduce drag, and airfoils for aerodynamic stability. The best rocket was the one with the aerodynamic upgrades. We could teach the kids the importance of air resistance.

Key Points

+ This project was a good opportunity to foster interest for science in young minds

+ It was also a good opportunity for bonding with lab mates.

Water Rocket – MDOUniversity of Toronto

I took a reading course on Multidisciplinary Design Optimisation with my Professor, Kamran Behdinan. During the completion of the course, I learned about optimisation algorithms and MDO architecture. To wrap off the course, I decided to come up with my own case study. I recycled the idea of a water rocket and expanded it to fit the needs for MDO problem. This case study was also intended to become course material for an eventual course on MDO.

I optimised 11 design variables, some discrete, to maximise the horizontal distance travelled by the rocket. Structural integrity and flight stability were imposed as constraints. Aerodynamic drag was considered as well. Thrust was calculated with the thermodynamics of water and air expanding in the cylinder.


Key Points+ I developed a case study for a reading course on MDO

+ I solved the MDO problem with MDF and IDF architecture, and used an Evolution Strategy optimiser.

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The problem was solved with two different MDO architectures:

1) MDF: Multidisciplinary Feasible

2) IDF: Individual Discipline Feasible

Evolution Strategy was the chosen optimiser for both architectures, mainly for its capacity to handle discrete variables.

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