Carbon Fiber Composite TPU Wheel

Version 1: 2023-2024

The first version of the wheel I designed consisted of a 3D printed TPU tread segmented into 12 pieces that were then adhered together around a pair of carbon-fiber composite shells with silicone RTV. In the previous year, the wheel diameter had been constrained by the working area of the 3D printer made available, however, by splitting up the tread, this was no longer the case (middle image depicts old prototype (top) and new prototype (bottom)). The Carbon-fiber shells were made via a wet-layup method with a vacuum bag over a 3D printed mold. Previously, the wheel dishes had been made with prepreg carbon fiber over an aluminum mold and then baked in an oven. 

Version 2: 2024-2025

The next iteration of the wheel was benefited by the purchase of a larger printer, allowing the maximum diameter to increase to 14" without sacrificing structure by splitting into multiple pieces. the wheel was also made assymetrical to tuck in the drivetrain more and decrease the chances that the motor and gearbox could snag onto rough terrain. Ribbing was also implemented on the interior to increase stiffness whilst decreasing mass to meet requirements.