Carbon Fiber Racing Wheelchair

Carbon Fiber

Racing Wheelchair

University design research project | Prototype

Objective

Design a high-performance racing wheelchair for paralympic athletes.

Phase I

Research & V1.0 Prototype

The first step, like any other product design process, was to acquire relevant information that, later on, helps to ideate solutions. The high-performance and paralympic concepts gave the project the main ideation guidelines to follow. Lightweight and resistant materials had to be a must in the project. Additionally, the production process had to be as simple as possible due to the low quantity that the hypothetical series could have implied.

Consequently, the team ideated that, for the first prototype, the best way to achieve this was to create a main carbon-fiber structure and the remanent components out of similar technical characteristics. The chassis structure was decided to be made in 2 main pieces (the main "T" shaped chassis and the fork).

To create this first prototype, a model out of a machined MDF piece from a 3D model was created, to craft the fiberglass molds that later on were going to be used to make the final carbon-fiber pieces.

And that is how, with all the natural anecdotes in between, the project was born.

Phase II

V2.0 Prototype

For this second phase, the team opted to change the previous production method and adjust all the necessary functional aspects that the first prototype helped to spot.

This time, it was decided to make the carbon-fiber molds directly machined to reduce the production process steps and to have a more accurate resultant piece. Considering this, the carbon-fiber piece was redesigned to later obtain the molds as simple as possible. Two negative parts molds were created successfully with a very challenging to obtain partition surface. Epoxy resin was used to create the mold block for the first test.

Also, another difference in the crafting process from the previous one was the need to create custom air chambers to ensure a better pressure distribution during the molding/curing process. As the chassis pieces were conceived as closed surfaces to simplify its production, in order to make them, we needed air chambers that copy its inner shape the best way possible and, also, flexible enough so when it expands it lets create an even pushing outward pressure over the carbon-fiber and mold surface.

The complexity of the shapes and the non-traditional carbon-fiber experimentation (compacting the fiber creating the pressure "outwards" rather than an air voiding method) led to a very enriching product development and production experimentation experience. Many breakthroughs and new knowledge were possible due to this project and the V2.0 racing wheelchair finally was born by the perseverant effort of the team.