For our national car, we will be manufacturing five different cars, two of which we will race. Since all of the design adjustments were completed in a very timely manner, we began generating the g-code tool path for the CNC manufacturing of the car body a week after the state competition.
Stage 1: Front Wing & Wing Mounting Jig Manufacturing
This time, we will be 3D printing all of our front wings and manufacturing jigs in one print. Once again we will be using red PLA filament, since it does not warp, and it is strong enough.
Stage 2: G-Code Generation
To be able to CNC our car, we need to generate the toolpath for the CNC machine, which is known as G-Code.
Stage 3: Machining The Car Body
One we had generated the G-Code for the top and underside of the car, we began cutting the car body out of Balsa Wood, using a CNC Router Milling Machine.
Stage 4: Sanding The Car & Glueing On The Rear Wings
To ensure that our car has a smooth surface finish, we sand the car down. After the car was sanded down, we then glued our rear wings to the car body.
Stage 5: Priming The Car Body For Painting
Before we paint the car, we need to make sure the surface is as smooth as possible. To do this, we spray the car with primer and then sand the car down again.
Stage 6: Car Painting
To paint the car, we spayed it with blue paint, to keep with our team colours and renders. This time, however, we used an electric spray gun to achieve a more even finish on the car.
Stage 7: Car Assembly
After the cars had been painted, it was time to assemble them. We first glued on our front wing, using our custom mounting jig. We then attached the grommets, glued the wheels onto the carbon fibre axles, and then attached the wheels.
The cars that won us the title of the F1 in Schools Australian National Champions were then completed!