Mechanical Engineering
Click above to see Design Report
3D Printed Pedal
I designed this pedal to demonstrate the potential of 3D printing and topology optimization as a mean of light weighting parts for the Terps Racing Baja SAE team. The pedals are printed out of carbon fiber reinforced nylon-carbon composite (onyx). By utilizing 3D printing, I was able to achieve geometries that allowed the part to be simpler and smaller. The parts has comparable strength with machined counterparts, were easier to manufacturing, and reduced the cost to manufacture. The pedal was first used in the 2018 season, and led to many other parts created with similar technique and manufacturing.
A key design goal of the pedal was the adjustability to accommodate drivers of different sizes. The Baja car needs to accommodate drivers with heights of the 95th percentile male through the 5th percentile female. Previous pedal designs had used a folding pedal design, which unfolded to allow shorter drivers to reach the pedal. However, it resulted in such a large pedal swing that short drivers could not fully manipulate it. I created a modular design that allowed for the entire pedal and mount to be shifted forward or backwards to accommodate different drivers. I used topology optimization tools in Inventor to design the pedal. I then conducted a trade study to determine the benefits and disadvantages over other manufacturing techniques.
