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    2019

    What inspired me to make the design for the car is Zombies. We made our car based on if there was a zombie apocalypse. When I watch The Walking Dead, sometimes this commercial comes up that shows a car all upgraded and ready for a zombie apocalypse. I mostly love zombies so all I was thinking of when I was thinking of a design was the commercial with the car.

    Team 9: Zombie Hunters

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    Concept Sketch

    Concept Sketch

    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.

    Car Model

    Car 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 Prototype

    3D Prototype

    3D Printed Part created on a Stratasys 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 Design

    Mold Design

    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.

    Mach_Mold_09.jpg

    Mach_Mold_09.jpg

    Race Vehicle

    Race 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.

    Use the Navigation arrows below to view the images for this team. Click on the image itself for a larger view &more detailed description

    3D PDF File of Vehicle
    3D PDF File of Mold Inserts
    Mold Machining Video

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