Sujan Munver

I am the responsible engineer for the suspension system of Cornell's Formula SAE vehicle. Through the design cycle, I focused on refining the team’s newly reintroduced rocker + anti-roll architecture into a more tunable and more reliable package. The vehicle uses a pushrod-actuated double wishbone suspension with inboard dampers, rocker arms, and an anti-roll system designed to enable lateral load transfer distribution (LLTD) tuning.

My work centers on:

System Packaging + Architecture: Ensuring all part designs (links, clevises, rockers, anti-roll bar, jig plate) align with system-wide goals. Packaging decisions oriented around the monocoque, in-hub motors, steering, and aerodynamics.

Vehicle Dynamics Parameter Selection: Anchored the design around tire behavior, mass/CG constraints, and kinematic goals (camber behavior, roll center intent, steering feedback).

Designed Suspension Kinematics: Chose inboard/outboard pickup points to hit steering and camber targets (camber gain, camber steer, roll center behavior, Ackermann intent, etc.), while maintaining packaging/clearance constraints

Anti-Roll Bar (ARB) System Redesign: Evaluated multiple ARB architectures and modified approach after further stiffness analysis; Converged on blade-adjustable U-bar to hit stiffness targets while maintaining adjustability and a unified design.

Load Case Development: Created LapSim-based acceleration cases (cornering, braking, acceleration, combined events) and used software scripts to extract link load cases.

Testing and Validation: More to come during the spring semester during our driving campaign!

I led the development and execution of a camber compliance testing campaign to characterize and reduce unwanted suspension deformation under lateral cornering loads for Cornell Racing’s Formula SAE vehicle. Camber compliance—unintended wheel camber change due to elastic deformation of uprights, hubs, bearings, and control arms—directly impacts the tire contact patch, grip, and vehicle handling.

To address excessive compliance observed in the 2024 vehicle, I designed a dedicated test rig capable of applying controlled lateral loads to a corner assembly while measuring angular deflection using dial indicators. The rig was engineered to minimize its own deformation and ensure proper load alignment through the upper and lower ball joints, isolating compliance to the components under test.

The testing campaign combined classical mechanics (beam bending, static equilibrium, and compliance calculations) with experimental validation to correlate physical results with finite element models. Various test cases were used to assess hysteresis and detect non-elastic behavior or mechanical play. Results informed design changes to uprights, hubs, and control arms, improving stiffness, repeatability, and predictive accuracy of simulation models for the 2025 and 2026 cars.

This work closed the loop between theory and testing, enabling data-driven design decisions that improved suspension performance, model fidelity, and reliability.

The jig plate is a precision manufacturing fixture used in the fabrication of suspension links. It plays a critical role in ensuring the quality, consistency, and repeatability of the suspension system by accurately positioning components during welding. By securely locating and constraining parts, the jig plate minimizes dimensional variation, reduces manufacturing errors, and improves efficiency in the assembly process.

The focus of this design included improving welding access, easier part setup, enhanced manufacturability, and increased durability while maintaining tight alignment tolerances. These changes resulted in a more user-friendly and reliable tool that streamlined link production.

The Dynamic Equanimity 3D Printers Initiative (DE3D, "Deed") is a student-founded, volunteer-led initiative dedicated to designing and manufacturing accessible, community-centered solutions using 3D printing and rapid prototyping. The project began during the COVID-19 pandemic in response to critical shortages of personal protective equipment (PPE) for healthcare workers, first responders, and educators. Leveraging skills developed through my school’s robotics team, I designed a reusable, comfortable, and material-efficient face shield that could be produced locally on consumer-grade 3D printers. Through iterative testing and feedback from medical professionals, the design balanced usability, safety, and environmental sustainability.

What began as an emergency response effort has since evolved into a broader mission focused on assistive technology. DE3D now collaborates directly with disabled community members to identify unmet needs and co-design practical, customized solutions that improve accessibility and independence. Guided by principles of human-centered design, the initiative integrates user research, prototyping, and real-world testing to create meaningful, scalable impact.

Impact & Contributions

• Designed and manufactured over 5,000 pieces of PPE using additive manufacturing and rapid prototyping, distributing equipment to first responders, hospitals, schools, and vulnerable individuals during COVID-19.

• Engineered and iteratively prototyped assistive technology devices for individuals with disabilities, including easy-touch buttons and ergonomic cup holders, applying human-centered design principles.

• Conducted user interviews and community outreach to identify needs, informing design decisions and improving usability, accessibility, and adoption of solutions.

I conducted translational cancer research at the intersection of precision medicine, tumor biology, and bioengineering, with the goal of bridging fundamental discovery and clinical application. My work focused on developing and utilizing organoid models derived from both human patient samples and mouse tissues to more accurately recapitulate tumor growth. These systems enabled more physiologically relevant studies compared to traditional cell cultures and supported personalized approaches to understanding disease.

To improve experimental robustness and scalability, I designed and refined culture platforms, optimizing conditions for organoid growth, maintenance, and high-quality data generation. I also established and implemented transwell assays to model cell–cell interactions, barrier function, and microenvironmental influences within tumor systems.

In parallel, I synthesized and tested novel drug compounds, systematically evaluating their therapeutic efficacy across both organoid and conventional cell-based models to inform clinical decisions. Throughout the project, I collaborated closely with local hospitals and clinical partners to integrate patient-derived materials and clinically relevant perspectives.

Many of my presentations below are (or will soon be) associated with written abstracts and articles published in peer-reviewed journals.

"Socio-Ethical Impacts of Artificial Intelligence in Medicine in Underserved Communities."

“Application of Artificial Intelligence in Surgery to Enhance Decision Making.”

“Combating physician burnout: Protecting the physical health and mental well-being of surgeons through preoperative COVID testing in patients undergoing minimally invasive surgery.”

“Burnout among minimally invasive surgeons prior to COVID-19: Results from a multispecialty survey of The Society of Laparoscopic & Robotic Surgeons.” 

“Mobilizing and Empowering Students to Run Large-Scale Efforts.”

“Physician Well-Being: Combating Burnout, Promoting Wellness, and Developing Resilience.”

• Department of Medicine Grand Rounds, February 11, 2021.

• Department of Pediatrics Grand Rounds, January 20, 2021.

• Department of Surgery Grand Rounds, October 20, 2020.

“Prevalence of physician burnout in urology: Disparity between peer reviewed articles and non-peer reviewed sources.”