Automotive design competition offers valuable hands-on learning opportunity for mechanical engineering students

Premier engineering design competition Baja SAE will take place in Gray Court, South Carolina, October 2-5, with 82 teams competing to have their vehicle prototype accepted for manufacture by a fictitious firm.

Now in its 50th year, the competition originated in 1976 at the University of South Carolina under the direction of Mechanical Engineering Professor John F. Stephens. His goal was to provide a hands-on learning opportunity for students that combined the application of stress analysis theory with the real-world industry concerns of manufacturability and time and cost constraints.

Ten universities, including USC, Arizona State University and North Carolina State University, competed in the inaugural Baja SAE, an event that has grown to three competitions each year under the sponsorship of the Society of Automotive Engineers (SAE) in locations across the country. Although the competition has changed in the last half century, the goal remains the same—to provide a hands-on learning experience that intersects academics with industry.

Baja SAE challenges teams of engineering students to design and build a prototype of an all-weather, rugged, single-seat, off-road recreational vehicle intended for sale to the nonprofessional weekend off-road enthusiast. Aside from functioning as a team to design, build, test, promote and race a vehicle, students must also resolve technical difficulties and generate financial support for their project. The event gives students first-hand experience as they manage real-life demands and priorities.

Alum Jay Evans, ’01, mechanical engineering, is currently a consolidated management system administrator for Coca-Cola Consolidated in Columbia. He participated in Baja SAE during the late 1990s and early 2000s, both as a competitor and volunteer, and is a co-organizer for the 2025 event.

“The Baja SAE Competition is an opportunity for students to apply what they are learning in the classroom to real-world situations,” Evans says. “It also offers practical experience that helps with finding a job, such as speaking with potential employers and making contacts with industry leaders.”

Although the Molinaroli College of Engineering and Computing is proud to serve as a sponsor for the October event, the college does not currently have a student team. Student participation is encouraged, as Baja SAE has been influential to many former students and valuable to those with an interest in gas-powered, all-terrain vehicles. Opportunities for hands-on learning is a topic often raised by prospective students.

“I feel privileged to meet with prospective students when they visit USC and to hear from our alumni on a regular basis. One of the most frequent questions I get is about opportunities for hands-on learning, and many students are particularly drawn to automotive-related projects,” says Mechanical Engineering Chair and Professor Travis Knight. “Baja SAE and similar activities provide exactly that kind of practical, team-based experience.”

The experience offered by Baja SAE has made a significant impact on the career trajectory of many alumni. In addition to hands-on learning, students network with event sponsors and volunteers, often leading to future career opportunities and sponsorship of their team. The competition also requires management and teamwork, important skills for any employment setting.

“The Baja competition was one of the key influences for me deciding to major in mechanical engineering,” Evans says. “It also influenced the projection of my career and helped cement some of my passions and career goals. This event is something for the college and especially the Department of Mechanical Engineering to be proud of.”

All engineering students are encouraged to be involved with Baja SAE and join the next generation of technical innovators in creating prototype gas-powered vehicles accepted for fictitious market. Students interested in forming a team for a future competition should contact Mechanical Engineering Professor and SAE Faculty Advisor David Rocheleau. 

“I am proud to highlight the college’s support for Baja SAE and similar activities,” Knight says. “Alumni often share with me how their participation in Baja SAE shaped their time at Carolina, gave them unforgettable memories, and signaled to future employers that they had the skills and determination to succeed.”