The Cal Poly Prototype Vehicles Laboratory (PROVE Lab) is a student-run organization that is devoted to creating world-record-breaking vehicles. I am a project engineering for "Project 2," also known as our Endurance Vehicle. This electrically powered sports car will travel 1000+ miles on a single charge, essentially quelling the modern electric car owners' "range anxiety." For the past 2 years I have been working on this team of engineers to create a design for this vehicle; we're now reaching the stage where we can begin manufacturing!
The photos above detail what we call a "mock-up," or a life-size to-scale model of the car in order to verify things such as seating angles, headspace, etc. Everything may look fine in CAD and work out in the equations...but it's good to double check and make sure everything physically feels right as well by actually building the interior space and seeing how you can move around in it.
This mock-up was made by taking 'slices' of the CAD model of the exterior shell ("aero shell") of the car and applying those profiles to sheets of plywood. Then, a team consisting of myself and two other engineers cut (with a hand router) the profiles of each section and put them together like a gigantic puzzle! We then could use the interior space to verify the seating angle, and other important measurements.