Steering Wheel

Completed April 2025

Car

  • TG21 (2024 season vehicle)

Materials

  • Carbon Fiber

  • Epoxy

  • Nomex® Honeycomb

  • 3D-Printed ABS

  • Grip Tape'

Innovations

  • Revised shape

  • Ergonomic implementation of radio button

  • Designed for two drivers to accommodate their unique driving preferences and ergonomics

  • Rated the most comfortable steering wheel by the team compared to previous vehicles’ steering wheels on our Driver Feedback Survey

  • Marked the first time for our team where a freshman designed and manufactured the steering wheel

Summary

The steering wheel not only has to endure the stress of repeated rotational motion inputted by the driver, but also must be comfortable for the duration of the grueling four-hour endurance race and high-intensity maneuverability track. For these reasons, comfort and durability were among my two highest priorities throughout designing and manufacturing.

  • In-house wet carbon fiber layup and 3D printed grips

  • Designed to last through all conditions and elements

Testing & Development

  • Initial Prototype

    This prototype was designed to model the previous generation vehicle’s steering wheel, though with changes to the corners’ radii to improve ergonomics.

  • Final Prototype

    An adjustment to the angle of the steering column made the initial prototype a poor ergonomic choice. This new prototype was developed to allow hand placement along three vertical tiers and an increased outer arc length, accommodating more styles of driving.

  • Carbon Fiber Prep

    The steering wheel core was constructed of Nomex and multiple layers of carbon fiber to provide maximum structural support.

  • Layup Prep

    The cut layers of carbon fiber and Nomex were brushed with epoxy and stacked with alternating direction of their weave. The stack was placed under multiple bags, cushions, and membranes so that a vacuum could remove excess air and create a strong seal between layers.

  • Completed Layup

    The carbon layup, once compete, was comparable to a solid block. It was water-jetted to create the shape of the steering wheel’s core.

  • Completed Steering Wheel

    The steering wheel after a competition. It reads “Eject” next to the radio button for a little humor!

Accomplishments

  • My steering wheel steered the car to victory, helping us win each competition and the overall season. This marked the first time that our team won 1st place at the conclusion of a season.

  • My steering wheel had the highest hand comfort rating compared to the team’s previous vehicles, rating 14.4% higher than the 2nd most comfortable wheel.