Case Study: Formula Electric at Berkeley achieves 20% part weight and cost savings and best-ever competition ranking with Fictiv

How Fictiv Sponsorship Empowers Formula Electric at Berkeley

Formula Electric at Berkeley (Formula Electric) is a 100% student‑run UC Berkeley team that designs, builds, and races a Formula EV. Lacking hands‑on manufacturing experience, the students struggled with designing manufacturable parts, choosing materials, and setting appropriate tolerances for critical components like uprights, sprockets, motor shafts, steering column, and battery structural bars. They partnered with Fictiv for CNC machining, design‑for‑manufacturability (DFM) analysis, materials expertise, and cost‑down guidance.

Fictiv provided regular mentorship and DFM consultations, machined precision components, and helped optimize material selection and tolerance stack‑ups while the students iterated through assembly and testing. As a result of Fictiv’s guidance and parts—including perfectly splined sprockets and motor shafts—the team reduced part weight and costs by about 20%, eliminated previous chain engagement issues, and achieved their best‑ever competition ranking and score, while the students gained crucial manufacturing skills.

Formula Electric

Can Aydin

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