Construction Summary
The majority of the part construction for this project involves utilizing 3D printing for the small components of the suspension. This advanced manufacturing method contributes to enhanced efficiency and effective time management. Additionally, the project relies on the expertise of band saws, hand saws, vertical mills, and drill presses, all of which play a crucial role in ensuring the overall success of the endeavor.
Drawing Tree
The drawing tree provides a guide of how each indivuidual part was assembled in a predetermined order.
Part Construction
The part construction provides an image of each part and a description of how the part was assembled and the processes that were used.
Figure 1 - Control Arm Moount to Steering Knuckle with Ball joint was constructed by heating the PLA+ plastic very slightly to soften the material. Quickly, the ball joint was pressed in and the outside of the part was formed along the ball joint for proper fitting.
Figure 1: Control Arm Mount to Steering Knuckle with Ball Joint
Figure 2 - The part construction consists of the lower control arm piece that connects to the rear knuckle. The lower control arm piece is then connected to the steel control arms, which are then connected to the control arm mount that connects to the body of the car. The process of assembling these parts consisted of press-fitting each part until it reached the backing of the holes.
Figure 2: Bottom Back Piece to Control Arm to Control Arm Mount
Figure 3 - The construction of the steering knuckle consisted of the 3D-printed steering knuckle and the attached fasteners. The steering knuckle was printed out of PLA+. Once the print for the knuckle was complete, M3 copper inserts were pressed and fitted into the upper and lower holes. This allowed the opportunity to thread in the pink ball joints, which would eventually mount to the control arm mounts. Lastly, the blue end of the steering tie rod was press-fitted into the hole, and a screw was entered through the tie rod so that it would be fastened into place.
Figure 3: Steering Knuckle
Figure 4 - The part construction for the rear knuckle was pretty simple as it consisted of the 3D printed rea knuckle and the fasteners attached. The rear knuckle was printed out of PLA+. Once the rear knuckle was printed, an M3 copper insert was pressed into the top hole, and a pink ball joint was fastened into it, creating the finalized rear knuckle.
Figure 4: Rear Knuckle
Figure 5 - The construction of the steering system consisted of the steering link and two swivel pieces mounted on a column designed on the car's chassis. The link and swivel pieces were 3D printed and made from PLA+ filament. The swivel pieces were fastened with bolts for each. Additionally, steering tie rods were attached to the ends of the link by a press fitting method, and they were fastened with a bolt to ensure they were secured.
Figure 5: Steering System
Construction Videos
Video 1: The steering components that allow the car to turn are being constructed in this video. The method used involved adding tie rods to all necessary parts, which required a press fit and a bolt for fastening, and following that would be attaching the swivel pieces to the steering link. Once all components are attached, it is ready to connect to the servo and the steering columns, which are mounted onto the chassis of the RC Car.
Video 1: Steering Construction
Video 2: This video illustrates connecting the servo mounts to the servo. The servo mount is made entirely out of 3D-printed PLA+ material. The process involved lining up the holes and pressing a pin through each. Lastly, made sure that there was a tight fit for the mounts.
Video 2: Servo Mounting Construction
Video 3: This video shows the construction process of assembling the shocks onto the car's center support, called the C-channel. The C-channel had copper M3 inserts, allowing parts to thread into the hole and fasten securely. After the threaded inserts were press-fitted, the shocks aligned with each hole, and a bolt was inserted to fasten the shocks into place.