3D Printed RC F1 Car

Technical Objective

The objective was the engineering of a functional remote-controlled (RC) racing platform utilizing multi-material fused deposition modeling (FDM). The project focused on achieving precise mechanical tolerances for bearing integration and executing high-dynamic structural components in TPU.

Structural Engineering & Materials

The chassis architecture utilized a hybrid-material approach to balance rigidity and impact resilience:

• Primary Chassis & Aerodynamics: High-rigidity PLA, modeled for optimal component density and aerodynamic fidelity.
• Kinematic Interfaces: Integration of press-fit stainless steel bearings into 3D-printed hubs. This required a series of tolerance-calibration prints to achieve a perfect interference fit, significantly reducing rotational friction compared to standard printed axles.
• Passive Suspension: Custom-printed TPU (Thermoplastic Polyurethane) components. This was the first operational validation of TPU for structural vibration damping and flexible mechanical links in this portfolio.

Hardware Specification

• Propulsion: Salvaged brushed motors and ESC from an auxiliary donor platform.
• Control Link: FlySky 2.4GHz radio system.
• Wheel Assembly: Custom-profiled TPU tires with integrated bearing hubs.

Operational Assessment

The platform successfully validated the "design-for-press-fit" methodology and the viability of TPU for high-stress mechanical components. The car remains functional and serves as a primary display piece for structural multi-material integration. The mechanical insights gained regarding material tolerances were successfully ported to subsequent, more complex multirotor and prosthetic builds.