Product design / Ergonomics / Composites
Formula Student — Custom Steering Wheel
Design and manufacture of a Formula Student steering wheel combining ergonomic CAD development, carbon-fiber parts, composite tooling and SLS-printed structures.
Application
Formula Student racing
CAD tools
Fusion 360 / Creo
Manufacturing
Carbon fiber / SLS 3D printing
Engineering case study
Project overview
This Formula Student project developed a custom steering wheel for a race car. The CAD design considered the driver's interaction with the wheel, the mechanical assembly and how individual components could be manufactured.
The resulting construction combined a carbon-fiber front plate with structural components produced using selective laser sintering (SLS). Composite moulds were developed in Creo.
Design / Realization
From CAD to reality.
Compare the design model with the completed physical result.
Engineering development
Project image gallery
Additional project views, CAD development images and supporting material.
Project specifications
Technical details
- CAD software
- Fusion 360, Creo
- Design focus
- Ergonomics and modular assembly
- Manufacturing
- Carbon-fibre front plate and composite tooling
- Components
- SLS 3D-printed structural parts
Design considerations
The design emphasized ergonomics and modular assembly, with the steering wheel developed as an integrated product rather than as a single visual model.
- Ergonomic wheel geometry
- Assembly of multiple custom components
- Composite mould design
- Interfaces between carbon-fiber and SLS-printed parts
Manufacturing approach
Composite tooling was modelled in Creo to support production of the carbon-fiber elements. SLS 3D printing was used for structural parts, alongside a carbon-fiber front plate.
The project connected CAD development with the manufacturing steps required to turn the design into a physical steering wheel.
Engineering takeaway
Steering-wheel design brings together user interaction, material selection and assembly constraints. The project demonstrates how CAD models and composite tooling can be developed together for a custom motorsport component.
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