Mass manufacture:
A present client of mine wants to run a STEM event (Science Technology Engineering and Maths based) event for up to 140 students at the same time for a whole day. I have done a number of these events, developing ideas and training staff and often leading the day. The clients has a technician to cut parts and order specialist materials but not for this particular event. Originally this gravity powered car was to be made from sheet material, or using special huge cardboard pieces I had previously developed. To fit in with the time availabel to make the parts and source the other pieces, I designed this version below.
This version uses bought in 600mm wooden spars. These are joined first into three basic frames using an A4 sheet of laser cut cardboard pieces which also join the three frames into the final shape. Each laser cut piece is pre drilled with holes for the drawing pins which hold the pieces together while they glue and provide additional support while it is used. All other pieces are off the shelf components available from at least 3 major educational suppliers to minimise supply difficulties. With this design, and a bottle of water each, the students will all have a great learning experience competing in various activities