In Jeff Wilhite’s Engineering IV class at Punahou School, juniors and seniors are taking on the challenge of creating electric vehicles from the ground up. The project emphasizes rapid prototyping, teamwork and real-world engineering skills as students move from concept to construction.
The process begins with students on their laptops, where they use Onshape to create 3D digital models to map out their vehicle designs and use KiCad 9.0, an open-source software, to plan reliable circuit layouts and electronic systems. This digital stage helps teams visualize both the structure of the car and the integration of its electrical components before moving to the shop. Each team of three divides roles to keep the work efficient: one student focuses on the electrical systems, while two concentrate on design and fabrication.
With the plans in place, students transition from screen to shop. Using colored markers, they mark PVC pipes for drilling, then cut them with a chop saw and shape joints with a tube notcher. The pipes are glued and sanded to form the frame, onto which real wheels are mounted. PVC serves as an inexpensive and flexible stand-in for the steel that will frame the final vehicle, allowing students to prototype quickly and refine their ideas before committing to the full build.
The project reflects Punahou’s emphasis on problem-solving and collaboration. By building and testing prototypes quickly, students not only refine their engineering skills but also learn how to communicate, share ideas and adapt when challenges arise. The prototype stage ensures that their designs can be improved and strengthened before they move on to constructing a full steel-framed electric vehicle.
Later in the spring, the students will take the next step: building TIG welding steel tube-frame go-karts, driving them and racing them in the Academy Quad – a showcase of their hard work, creativity and engineering talent.
Photos by Kathleen Connelly