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The Idea
The creation of this project was sparked by me wanting to enhance my CAD skills and familiarize myself with the possibilities and limitations of my FDM 3D printer. Understanding the basic mechanics of steering, differentials, and power transfer involved in automobiles has always been an interest of mine and what better project would teach me such things than a remote-controlled car.
The Plan
Trying to single out what design I wanted to commit to was a challenge. Deciding what scale it needed to be, if it would have suspension, or component printability, etc. were all questions that needed to be addressed before and during the design phase.
Integration
Figuring a way for the car to steer simultaneously while one wheel is elevated requires a ball joint, a true material constraint. I realized using a large clearance fit on the tie rod end and the screw connected to the hub can replicate the same function as a ball joint. I also needed to integrate a 3D-printed bevel ring gear as the spur gear for the open differential gearbox did not fit my design parameters.
The Build
The 80+ part assembly of the car was broken up into two major sections, the front and the rear. After many reiterations to ensure tolerances were met the entirety of the car was put together using standard M3 screws and bolts making anyone able to print this project. I couldn't be happier with the appearance.
Improvements
To enhance power transfer from the motor to the rear wheels I plan on creating an aluminum ring gear and driver gear to increase mesh quality and longevity. In addition, to improve the structural integrity having the frame printed as one piece would reduce the shear stress experienced at each connection.
THIS PROJECT WILL SOON BE AVAILABLE FOR DOWNLOAD ON THINGIVERSE.COM
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