FFORMIWLA 3D PROJECT NANTGAREDIG

thingiverse

This is an adaptation of the Open RC F1 car with many design modifications to make it robust upon impact. The car is fully remote control enabled. The design allows for suspension with soft tyres and easy to handle. The body is strong to withstand collisions but not very heavy. It can drive fast depending on motor rating. The assembly is simple and quick requiring mainly cable ties. This would make an ideal educational project or a race event, and will attract the interest from young learners and their teachers, targeting all ages starting from primary school age groups. Technical summary describing design modifications: - For reliability I used metal gears (pinion and spur). - Less printable components by merging where possible, for instance the aerofoil and the front nose is a single item. - The front aerofoil has been considerably strengthened as well as the rear wing to withstand impact. Fastening using cable-ties allows for crush protection as they snap off in a sacrificial way saving the parts upon impact. The repair requires simply to fasten the nose & aerofoil back to the chassis with two new cable ties. - The front body panel is separated from the nose&aerofoil to protect upon major impact. It also helps in the overall balance with all wheels touching the ground even if the chassis is warped (could cause one wheel to lift off the ground otherwise). - The nose and aerofoil are not fastened to the rest of the panels (only to the chassis) protecting the middle panels during impact, while forgiving any warping on the chassis which in the original car it would result in one of the wheels lifting off the ground. - Innovative design merges wheels and tyres as a single item, adding much needed suspension and stability. Rubber sleeves from bicycle tubing are cut to side and put on each tyre for extra grip. - The front hubs were widened and strengthened (same diameter as the rear axle; sharing the same size bearings). - The rear axle has two flat planes for ease of printing. Importantly the rear axle holders are part of the motor cover, making it easy to remove the axle if needed. - The cabin allows for longer batteries to be used as the servo has been positioned further at the front. - The servo motor provides a direct steer via the flexible (but rigid enough) steering rod that connects the front hubs. - The flexible steering rod is printed in TPU to allow for rotational movement of the servo arm, while acting also as a servo-saver upon frontal impact of the wheel. - The lid (with driver head) is secured by clicking in place without needing the external clip fasteners. Assembly: Built instructions in the PDF/PPT presentation files below Bill of Materials: I) Electronic components - MG90 Servo - 2.4GHz radio transmitter and receiver (remote control) - RC Car Brushed Motor, anything from 80T (slow) to 35T (fast) - 320A Brushed ESC for Remote Control Car. You will need to change the connector to T-Plug (Deans Style) - LiPo battery with T Plug Deans Connector - LiPo battery USB balance charger 2S type - LiPo battery protection case II) Bearings, screws, accessories - 6 x Deep Groove Ball Bearing 12x18x4mm 6701ZZ (4 for the front wheels, 2 for the rear axle) - 15 x Cable ties 3mm (some extra are needed for repairs after front collisions - sacrificial to save the nose from breaking upon impact) - 1x Spur gear 48 Pitch 80T - 1x Pinion motor gear 3.175mm (shaft diameter) from 32 to 40T (number of teeth); 48 Pitch - 6 x M3 (3mm X 8mm) Socket Countersunk Screws Allen Key Socket (one for each wheel; 2 for securing spur gear to an attachment) - 2 x M3 (3mm x 25mm) Socket Button Screws Allen Key Socket (one for each hub; alternatively 2 long nails can be used) - 2 x M3 (3mm X 12mm) Flanged Button Head Screws Allen Key Socket (to secure the motor onto the car); can add 2 x M3 washers also - Hex Socket Screwdriver H2mm T Handle Wrench Allen Screws - Paper for sponsor logos to stick on cars: TerraSlate Paper 4 Mil Waterproof Laser Printer (simply print the logos using a normal laser printer and glue on) - PLA filament for body parts and chassis - TPU filament for wheels/tyres and steering rod