CCA’s Project Zephyr

One of the Innovation's Hub popular courses is Project Zephyr which gives students a fantastic opportunity to produce the best electric vehicle from scratch, embodying the spirit of both teamwork and competition. 

Project Zephyr takes students aged 12+ on a learning journey where they have the opportunity to delve deep into STEAM while also learning about business, law, marketing, teamwork, leadership and more.

Project Zephyr splits into two parts, the practical and the social, where students and staff discuss their discoveries during the practical part. Foamblock provides institutions with their mapping algorithm to aid students in discovering their individual paths after school. 

Utilising professional-grade tools available in the Innovation Hub, students craft in metal, plastic, wood, fabrics and other materials. During this process, they learn to use any substance that suits their needs using lathes, mills, CNC routers and conventional hand tools.

Each group is free to put into practice any design it pleases, limiting the project only to the materials, the pre-provided components (such as brakes, wheels, motors and batteries) and safety considerations. Other than that, the only requirement is that the car looks like a car and works like a car.

The entire experience is student-led, and this approach helped BSB students develop skills such as model making, scale prototyping and sculpture to gather vital competencies used in a number of high-end industries today. 

Part of the objective is to produce a car chassis, body and drivetrain. The car's body is manufactured using clay sculpting techniques as well as composite technology (fibreglass and carbon fibre) and various other industry methods. 

Teams are always encouraged to make improvements, adding whatever they deem worthy to their initial design. With a final product in place, the teams move on to testing and racing their cars. Once a team completes their vehicle, the best one is hoisted into the Innovation Hub showroom on the roof of the building, being displayed for the next academic year. All other cars are recycled almost entirely, and materials are reused for the next group of students.

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