In this design lab, our team was challenged to build a go-kart capable of supporting the weight of our professor, using limited materials: wood, PVC pipes, wheels of our choice, and a steering mechanism (internal or external).
Inspired by the design and riding position of Batman’s motorcycle, we developed a unique concept and performed hand calculations to determine the appropriate sizing for structural components. These initial calculations were validated using Finite Element Analysis (FEA) in SolidWorks to ensure strength and safety. The project offered a valuable hands-on experience in balancing creativity with material constraints and engineering rigor.
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With the use of finite element analysis within SolidWorks, we ran different iterations of load cases. From these, we determined the outer diameter and wall thickness to use for our required material of PCV tubing.
Our final go-kart design taught us valuable lessons in both manufacturing and material selection. One major challenge was tensioning the cables that connected each side. We successfully secured one side, but the other proved far more difficult due to assembly constraints and required the addition of a ratchet strap to add tension.
Additionally, our decision to transition from PVC to wood became a clear design flaw, as the connection between the two materials lacked strength and reliability. In hindsight, maintaining a fully PVC frame with reinforced joints would have improved both the structural integrity and overall ride quality of the kart.
