Ware Lab: Formula SAE Team
- Anna Lucas ('27)
- Apr 15, 2025
- 6 min read
At Virginia Tech, a group of students work late nights and early mornings, buzzing with the thrill of bringing a race car to life. It’s a formula-style race car built from the ground up by members of the Formula SAE team. Every part of the car is carefully designed, crafted, and tested by students, guided only by a bare-bones rule set provided by the Society of Automotive Engineers. These rules encourage the team to push the boundaries of creativity and technical expertise, challenging them to find inventive solutions to real-world engineering problems.
Over the course of a year, the team transforms their vision into reality, pouring thousands of hours into a car that will compete on an international stage. They’ll take their creation to the Formula SAE competition, where it will go head-to-head with roughly 130 other university-built cars from around the globe. There, the team will face rigorous assessments as they will be inspected on varying technical elements from the engine design to the structural integrity of the chassis.
The car will also be judged on its performance in dynamic events, such as acceleration, skidpad, autocross, and endurance, which all test the vehicle’s handling, speed, and reliability under pressure. The team will then be evaluated on their design presentation, where they explain their engineering choices, cost analysis, and business strategy to a panel of judges. In 2023, Virginia Tech placed 7th in the highly competitive competition, showcasing the team’s ongoing excellence. The team’s legacy is also highlighted by their remarkable achievement in 1991 when they took home the ultimate prize and were crowned the 1st overall, a testament to their long-standing commitment to innovation and excellence in engineering.
The stakes are high for these young engineers, but so are the rewards. The experience doesn’t just build technical skills; it’s a springboard to future success. Many team alumni have gone on to work at some of the world’s most iconic engineering and aerospace companies, including Boeing, SpaceX, Lockheed Martin, Formula 1, and NASCAR. For students on the team, Formula SAE is more than just a project, it’s a journey into careers that shape the future of engineering and technology.
That journey starts with hands-on experience, something many students wouldn’t get in a traditional classroom setting. Henry “Hank” Pate, a sophomore in engineering, reflected on how being part of the team has expanded his skill set in ways he never expected.
“I knew almost nothing about composite structures, and now I have real-world experience with the entire design and construction process,” he shared. “Going into it, I didn’t know that carbon fiber was laid in varying angles for strength, and now I can design laminate structures based on the specific needs of a piece.”
-Henry “Hank” Pate
Through trial and error, students like Hank transform their curiosity into expertise, proving that learning doesn’t just happen in the classroom but in the workshop alongside teammates who push each other to be better engineers. That growth isn’t just individual, it’s deeply tied to the collective effort of the team. Every student brings their own strengths, but no one builds a race car alone.
From the first sketch to the final test run, every student plays a role in bringing the car to life. It’s a project that demands more than just technical knowledge; it thrives on collaboration. Aerodynamics experts shape the car’s body while suspension engineers fine-tune its handling. Marketing students secure funding, and programmers refine data analysis. Every discipline has a place, and every contribution matters. Whether you’re an engineer, a computer scientist, or a business strategist, there’s a role for you in crafting a machine built for competition. As Pate put it, “Being on a team this big, it’s natural to encounter people with different work styles and backgrounds. Learning to be an effective worker, even when the way you do things differs from others, is preparing me to be effective no matter the working climate I join.”
That’s the nature of building something this complex; no one can know everything. Instead, success comes from trusting the expertise of those around you. “There are so many things on this team that I don’t know, and that simple fact means I have to rely on the work and experience of others,” Pate shared. “It’s made me a better engineer because, in any meaningful task, you can’t possibly know every small detail. Learning to let go, trust your teammates to do their roles, and focus on your own is something I’ve truly internalized through this experience.”
Learning to trust teammates is vital, but just as important is the willingness to pass that knowledge along. No one joins Formula SAE knowing everything, and for new members, the amount of components and the knowledge needed to handle them can feel overwhelming. That’s where the more experienced students step in, not just as teammates but as mentors. They teach newcomers how to run simulations, troubleshoot issues, and refine a design until it is competition-ready.
“Seeing recruits come in at the beginning of the year, some knowing a bit and others none at all. By the end of the semester, while they still have a long way to go, the ones who are dedicated enough, you can see it in their eyes—they understand what we do here and utterly love it. It feels extremely rewarding when you see that spark of interest start and help guide them to a new passion.” Hank Pate said.
In Formula SAE, beyond just learning, many discover what truly interests them. Whether it’s the precision of machining, the creativity of design, or the problem-solving of data analysis, Formula SAE gives students a chance to find what they love and teaches them the dedication it takes to master it. What starts as an extracurricular activity quickly becomes a passion, shaping both their education and the careers they’ll one day pursue.
And major companies know this. The hands-on experience, problem-solving mindset, and ability to work under pressure make Formula SAE alumni stand out in the job market. Employers recognize that these students don’t just learn engineering; they live it, facing real-world challenges long before they step into the workforce.
“There are quite a few companies at a job fair that will star or circle any FSAE resume, especially for VTM, as we hold one of the most difficult recruiting processes. Simply being on our team means to employers this person is a good enough option to warrant an extra look. It’s a reputation we work quite hard to maintain, as it is one hard-earned over the last thirty years of our team’s history.” Hank Pate said.
Students in Formula SAE aren’t just learning theories in a classroom; they’re applying them in a setting where every design decision has tangible consequences. Whether it’s optimizing aerodynamics, sourcing materials, or managing sponsorship deals, members gain the kind of hands-on experience that makes them highly sought after in the job market. “Simply put, design teams are the only place where the entire design process can be modeled. The economics, design, life cycle, and manufacturing are actually done with nothing being considered hypothetical.” Says Pate. “FSAE includes every step and consideration when designing your part. For hypothetical teams or research, often the economic or manufacturing considerations are overlooked. With FSAE, this is not possible because the pieces must be bought, built, and run through their paces with a real human driver. This just means that for 3-4 years, people who are a part of FSAE are gaining experience in designing the way the industry designs, and that is extremely attractive to potential employers.”
Formula SAE at Virginia Tech is more than just an opportunity to build a race car, it’s an experience in real-world engineering, problem-solving, and teamwork. As students face the challenges of assembling a car from scratch, they learn to think critically, communicate effectively, and approach problems with creativity and precision. The design evolves, and with each iteration, the car becomes a manifestation of countless hours of hard labor and teamwork.
By the time the competition arrives, the students aren’t just engineers, they are a unit of problem-solvers and innovators, equipped with hands-on experience that far surpasses what they could gain in a classroom. The journey itself becomes a valuable part of their growth, preparing them for careers where these skills will set them apart. The process of working together to create something from the ground up teaches them lessons that will stay with them long after the race is over.
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