The concept for our racecar given by our Broughal students is the body of a sea turtle, with a jellyfish riding on top. There are also two small fish on the side of the body of the turtle. The turtle doesn’t have any legs, but just the wheels attached at the bottom of the body. The body of the turtle is most of the design, with the additions of the jellyfish and the fish on the sides.

Team 21: Team Turtle Time

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Vehicle Concept

Vehicle Concept

The concept sketch is provided by the Broughal “customers” and is the basis for the vehicle design. After some discussion and possible modification, the concept will be rendered as a CAD model by the Lehigh team members.

CAD Model

CAD Model

SolidWorks CAD rendering of the vehicle concept. The CAD geometry will be used to create the cavities in the injection mold plate inserts. Wheels and a color scheme have been added for show.

3D Printed Prototype

3D Printed Prototype

3D Printed Part created on a Makerbot 5th Gen Fused Deposition Modeling (FDM) machine. The prototype is printed directly from the CAD model file much like a page is printed from a document. In this case the FDM is printed in three dimensions, in very thin layers from the bottom up. The prototype can be used to assess the size and design features of the vehicle as well as to test out some paint schemes. One could even attach wheels to get an idea of the overall look and speed of the vehicle.

Mold CAD Model

Mold CAD Model

SolidWorks rendering of the mold inserts. The mold geometry includes the cavities for the vehicle plus the runners and gates which allow the polymer melt to flow into the cavity during molding. The larger holes in the corners of the molds will be used to secure the inserts to the mold base. The mold geometry is ready to be imported into the NX CAM software to create a set of toolpath instructions for machining.

Machined Molds

Machined Molds

The finished mold plates have been machined on the HAAS NC milling machine and are ready to be mounted in the injection molding machine. Note the small holes in the mold cavity. The holes will be fitted with ejector pins used to eject the cooled part from the cavity at the end of the molding process.

As Molded Vehicle

As Molded Vehicle

This is molded vehicle as it looks when it is ejected from the mold on the injection molding machine. The vehicle is ready for assembly (if needed), paint & wheels.

Race Ready Vehicle!

Race Ready Vehicle!

Finally, the car has been painted and the wheels have been attached. Weight may be added to the actual race vehicle to bring it up to the maximum weight limit of 40 grams. After that, the vehicle is ready for some trial runs on the practice track.