Custom Lightweight Brake Pedal
Solstice needed a shorter brake pedal than most off-the-shelf components, so I designed a custom shortened brake pedal with adjustable pedal ratios to fit our driver pod.
Design modifies an existing Wildwood brake platform to have custom length and pedal ratio according to braking pressure calculations
Calculated braking forces, Designed in SolidWorks,
FEA using Ansys, CNC Machined in 7075 Aluminum
Machined on 3-axis VF2, required 5 setups with multiple custom fixtures
$1000 saved compared to outsourcing design+manufacturing
Swing Arm and Uprights
Machined from 7075-T6 aluminum on a 3-axis CNC mill. Parts required tight bearing bore precision for press fits and multiple setups to accurately machine all geometries.
Shared CNC Tooling Library
Created Documented a library of all available CNC tooling at our shared shop in Fusion 360. Simplifies machining and tool selection workflow for all sub teams during manufacturing
Includes tested and verified feeds and speeds + shared spreadsheet to track replacement tooling from breakages.