IAN BETTIS / PORTFOLIO
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Complete Zephyr Baja SAE carZEPHYR / MANUFACTURING DIRECTOR

BAJA SAE / CAR 02 / MANUFACTURING DIRECTOR

Zephyr Leading manufacturing. Making the complex parts.

For Zephyr, I served as Manufacturing Director. I reviewed designs and made sure team members were trained on the different machines they would use. My main responsibility was manufacturing complex CNC parts, combining hands-on machining with the coordination needed to support the rest of the team.

My role & the manufacturing process

Design reviews

I went through design reviews with the team, considering how components would move from a design to a manufactured part.

Machine training

I made sure team members received training on the different machines, helping them build the skills needed to contribute in the shop.

Complex CNC components

My primary focus was making the more complex CNC parts. The work below documents gearcases, hubs, uprights, custom calipers, and other components through different stages of manufacturing.

From prototype to vehicle

The build progressed from 3D printed mockups through frame fabrication and machining to vehicle assembly. This collection follows that progression.

01 / 3D printed parts & prototypes

3D printed bearing cup mockup
3D printed bearing cup mockup
3D printed upright mockup
3D printed upright mockup
3D printed prototype gearcases
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02 / Welding & frame manufacturing

Frame manufacturing in the welding jig
Frame manufacturing in the welding jig
Frame fabrication progressing in the jig
Frame fabrication progressing in the jig
Zephyr frame out of the welding jig
Zephyr frame out of the welding jig
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The manufactured frame alongside scale models
The manufactured frame alongside scale models

03 / Complex CNC machining

Steering case setup
Steering case setup
Front gearcase machining
Front gearcase machining
Front gearcase - third machining operation
Front gearcase - third machining operation
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Rear gearcase machining
Rear gearcase machining
Bevel case machining
Both front gearcase halves machined
Both front gearcase halves machined
Front and rear gearcases during machining
Front and rear gearcases during machining
Finished gearcase halves
Finished gearcase halves
Finished gearcases and drivetrain components
Finished gearcases and drivetrain components
Front hub - first machining operation
Front hub - first machining operation
Front hub - second machining operation
Front hub - second machining operation
Front hub machining setup at Boyd Lab
Front hub progression from stock to finished part
Front hub progression from stock to finished part
CNC machining an upright
Chip removal during upright machining
Upright manufacturing
Custom caliper machining
Custom caliper machining
Custom calipers after the first machining operation
Custom calipers after the first machining operation
Multiple calipers progressing through machining
Multiple calipers progressing through machining
Custom caliper - second machining operation
Machined custom caliper components
Machined custom caliper components
Custom caliper prototypes and machined parts
Custom caliper prototypes and machined parts
Machined sway bar arms and calipers
Machined sway bar arms and calipers

04 / Assembly, complete car & team

Suspension installed on Zephyr for the first time
Suspension installed on Zephyr for the first time
Full suspension mockup during vehicle assembly
Full suspension mockup during vehicle assembly
Wheel assembly
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Zephyr with its first vehicle wrap
Zephyr with its first vehicle wrap
Zephyr and the Iowa State Baja SAE team
Zephyr and the Iowa State Baja SAE team
The team and vehicles at Backwoods
The team and vehicles at Backwoods

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EMAILiabettis@iastate.eduLINKEDINConnect with Ian BettisRESUMEDownload my current resume