Car 02 · In Development

Sunburst

Racing 2026

Car-2 Sunburst

Ground-Up Redesign

A complete redesign from CAR-1. New aeroshell validated at the Stellantis wind tunnel in Auburn Hills, Maxeon Gen7 solar cells, and a Samsung INR21700-50S battery pack managed by an Orion BMS 2.

64 mph top speed
332 mi range
280 kg loaded
5.23 kWh pack
Manufacturing process 1 Manufacturing process 2 Manufacturing process 3 Manufacturing process 4 Manufacturing process 5

Generation by Generation

Evolution

Three generations of solar racing engineering at Badger Solar.

Car-1 Car-1.5 Car-2
Weight 364 kg 320 kg 280 kg
Height 1.70 m 1.50 m 1.31 m
Length 4.42 m 5.10 m 5.75 m
CD × A 0.113 m² 0.098 m² 0.087 m²
Drag Force 39 N 34 N 30 N
Battery 4.02 kWh 4.60 kWh 5.23 kWh
Solar Area 4.6 m² 5.3 m² 6.0 m²
Motor Power 1.5 kW 1.8 kW 2.0 kW
Top Speed 49 mph 56 mph 64 mph
Range 255 mi 290 mi 332 mi

Engineering

Under the Shell

Aeroshell

Wind tunnel tested at the Stellantis facility in Auburn Hills. Aeroshell and roof molds CNC milled in-house from foam plugs.

CD×A 0.087 m² Drag 30 N Length 5.75 m

Solar Array

Maxeon Gen7 monocrystalline cells from SBM Solar, wired through a custom solar array PCB designed and assembled by the team.

Area 6.0 m² Maxeon Gen7

Battery

Samsung INR21700-50S cells, characterized on a Maccor cycler and managed by an Orion BMS 2. Spot welded into a custom pack.

5.23 kWh Orion BMS 2

Powertrain

Mitsuba M2096-DIII hub motor controlled by a custom powertrain board (Rev E). Direct drive with no gearbox or chain.

2.0 kW Direct drive

Electronics

Custom power distribution controller, LED lighting boards, and CAN bus network. Telemetry over LTE (Quectel EG25-G) and 915 MHz radio (RFD900A).

Custom PDC CAN Bus LTE Quectel EG25-G RFD900A 915 MHz