Scalextric Car

Unai Urgoiti - Şevval Ayan - Yiğit Çapkin - Dilara Özcan

Intro
The essence of our project goes beyond the mere convergence of three manufacturing
technologies; it seeks, at its core, to comprehensively explore different production
modalities. Initially, the original conception of our project involved the creation of a remote-
controlled car; however, upon evaluating the complexity associated with this proposal, we
opted for a strategic redefinition. This transition led us towards the ambitious goal of
manufacturing a Scalextric car, thus setting the definitive course for our project.

In order to fully incorporate the capabilities of three manufacturing technologies, we

The project concludes with the implementation of a box specifically designed to house our
Scalextric car, thus representing laser cutting, our third technology. This report aims to
examine in detail the manufacturing process, addressing the fundamentals behind our
design decisions.

Base
The design of this piece was done in SolidWorks. It was decided to use 3D printing due to
the ability of the technology for creating quick prototypes with any shape.
This piece has many special points, as it has to sustain both axis of wheels, a magnet, the
motor, the guide and the rails for the electricity to flow.

This pieces will not be made by us, as that will not be part of the assignment, but we will take
them our of older cars.

We will try to replicate a base of a slot car, adapting it to our necessities and tolerances.

Fabrication:
In order to obtain this piece, it had to be done 3 times.
The first error we encountered were that the motor and wheels did not fit properly, neither
the magnet and the guide was too loose.
Then, after redesigning the piece, we printed again. This time, we could fit the motor, the
magnet and wheels, and we solved the looseness of the guide. However, the wheels were
too high and it was not functional yet.
After the third print, we could assemble everything and it worked fine.

The plane of the piece will be added at the end of the document, with all the dimensions and
tolerances.

Additionally, some Leds were soldered to the base and then glued to the case.

Fabrication Values:

Setting Value

Layer Height 0.1

Wall Thickness 0.8

Top/Bottom Thickness 1.6

Infill Density 20

Printing Temperature 215

Print Speed 30

Enable Retraction True

Z Hop When Retracted False

Enable Print Cooling True

Generate Support True

Support Pattern Lines

Support Density 50
Build Plate Adhesion Type Skirt
Case
Design:

The design of the casing was entirely done in Blender. When deciding on the project idea,
the choice to use 3D printing was quickly made as it was the only technology that offered the
desired results.

The decision to opt for creating a simple model with not too many polygons was also
straightforward. It was wisely decided that properly printing the model would be challenging
enough without adding complexity to the piece.

Therefore, the decision was made to take reference from older cars, which tend to have
more flat surfaces compared to contemporary cars that are more rounded. Nevertheless, at
no point was a specific car used as a reference; rather, the focus was on the general
aesthetics of these vehicles.

Fabricación:

Unfortunately, the manufacturing process was neither quick nor smooth. Given the project's
difficulty, numerous problems arose in both design and fabrication. The casing had to be
manufactured up to six times, of which only three were our fault, while the rest were
attributed to material or machine issues.

On occasions when we had no involvement, one instance resulted in half of the car being
printed, but the material ran out before completion. When attempting to change the material,
the remaining portion had expanded due to humidity and became unusable. The other two
instances only printed the initial layers, likely due to the base temperature and material
issues.

In the cases where we had to reprint due to our errors, two of them were to modify the
design so that it could be seamlessly used with the base. It was crucial for the model to fit
well onto the base. Another manufacturing attempt failed because, when changing the
printer in Ultimaker Kura, some support settings were reset, making them too thick and
impossible to remove.
In each iteration, we took the opportunity to improve the overall model, adjusting dimensions
and small details such as the connections between the casing and the base. Additionally, we
experimented with different types of supports because, given the structure of the model,
some were challenging to remove. We ended up using line supports, which proved to be the
easiest to remove.

Fabrication Values:

Setting Value

Layer Height 0.2

Wall Thickness 0.8

Top/Bottom Thickness 1.6

Infill Density 40

Printing Temperature 215

Print Speed 40

Enable Retraction True

Z Hop When Retracted False

Enable Print Cooling True

Generate Support True

Support Pattern Lines

Support Density 15

Build Plate Adhesion Type Skirt

Stickers
Box