The project to build an FSAE vehicle was carried out in Department of Mechanical Engineering, Chandigarh University to compete in the Formula Bharat 2018 – A national level competition, held at “Kari motor speedway”. The process used for design and manufacturing of the open cockpit formula student race car, along with considering the driver’s safety, was optimized based on material selection, manufacturing processes, selection of drivetrain, differential and gear ratio. Further, to achieve the maximum power output in terms of acceleration and top speed, various simulation processes were done in advanced simulation and designing software and discussed.