Sixthform engineering challenge - autonomous solar powered line following robot

[rob_j_s]

Model uploaded to Creality Cloud - Creality Cloud -Engineering challenge chassis v3 (friction fit) + … From user5681115635 Engineering challenge chassis v3 (friction fit) + mounts | 3D models download | Creality Cloud

Designed as a two part friction fit chassis to avoid the need for supports.

Printing Machine: Prusa Mk3 (as only printer available at school)
Selected materials: PLA
Print settings: 0.2mm and standard settings (no supports needed as a two part friction fit lid)
Time spent on printing: circa 4 hours
Description: Two part friction fit chassis as part of school project. Details as follows (and attached)
I’m a Maths teacher (11-18) in the UK and began my journey into 3D printing a year ago. This was as I created and trialled an engineering challenge for sixthform students (17-18) where from a standardised chassis, they were challenged to work as a small team of 2-4 students to create an autonomous solar powered line following robot (more detail below + videos + materials). This introduced them to a range of skills not taught in the classroom, requiring them to develop skills in 3D design, 3D printing, programming and project management. I’m passionate about multi-disciplinary integration in engineering and view 3D printing (and rapid prototyping) as a key element of this.

More photos to follow (I’m away for a few days but will update 23 Aug)

Last year I successfully trialled the engineering project with four teams using the school’s 3D printer to produce the chassis’ and print the students designed parts – solar panel mounts + their design for mount of IR sensors. They learned lots along the way, with lots of trial and improvement, and developed a range of key engineering and team working skills. I have taken a job at a new local school from September and whilst I hope to continue the project, unfortunately I won’t have the same access to 3D printers at my new school so winning a K2 Plus Combo or Ender-3 V3 would transform my ability to continue and develop the project. Assuming continued success (and refinement of the project) in the longer term I have aspirations to extend the project to other schools in my local area.

For a little more context please review the attachments provided – you’re welcome to use but please do include me as a reference on this. I’d also welcome any thoughts, feedback or development suggestions.

The whole project has come about as a response to my previous school having no Design and Technology department, but a strong STEM cohort of students. Many of these were applying to University or for apprenticeships to study Engineering or practical science degrees, but the lack of practical experience available through meant they were struggling to get through the application process. The engineering challenge was an effort to address this practical skills gap.
Provide relevant originality proof: As posted to Creality Forum (STL files provided) - Creality Cloud -Engineering challenge chassis v3 (friction fit) + … From user5681115635 Engineering challenge chassis v3 (friction fit) + mounts | 3D models download | Creality Cloud
Country/Region: UK

Examples of student produced materials:
Project briefing document - Challenge 1 v2 Y12 Jan 24.pdf (264.4 KB)
Engineering challenge - Project Charter student example.pdf (297.8 KB)
Engineering challenge - Student project presentation example 1.pdf (1.2 MB)
Engineering challenge - Student project presentation example 2.pdf (1.2 MB)

[rob_j_s]

UPDATED with photos - with apologies, but I cannot edit my own post as I’ve left it too long.

**I’m an Educator in the UK (Maths teacher for 11-18s) who has spent the last year learning to use 3D printing with a view to use this as a method of introducing students to Design, Rapid Prototyping and Engineering - a gap at my current school which has no Design and Technology department, but owns a 3D printer. This has taken various forms for different year groups, but most notable has been the creation and trial of an engineering challenge for sixthform students (17-18) where from a standardised chassis (with lots of different fixing options), they were challenged to work as a small team of 2-4 students to create an autonomous solar powered line following robot (more detail below + videos + materials) which includes 3D design and printing of IR mounts and a solar panel mount. This introduced them to a range of skills not taught in the classroom, requiring them to develop skills in 3D design and 3D printing, as well as electrical/ mechanical engineering, programming and project management for the full project delivery. I’m passionate about multi-disciplinary integration in engineering and view 3D printing (and rapid prototyping) as a key element of this. 3D printing has been a key enabler as cost pressures are incredibly tight and each teams kit cost needs to be minimised - target of £40 per team. 3D printing all parts of the robot enables this to be achievable.

The biggest reason this competition would help for me, is that in September I have taken a job at a new local school and whilst I hope to continue the project, unfortunately I won’t have the same access to 3D printers at my new school so winning a K2 Plus Combo or Ender-3 V3 would transform my ability to continue and develop the project. Top of my list of developments would be new wheels (with an indent for an elastic band) and a redesigned two part snap fit chassis. I’ve already changed to analogue IR sensors and would also wish to look at a most to a Pico Pi from the current Arduino (but not 3D printing related). Assuming continued success (and refinement of the project) in the longer term I have aspirations to extend the project to other schools in my local area.**

**2. The K1 Max is currently discounted in the back to school sale to £639 in the UK (£859 at full price) **

3. Forum post here - Photos and a short video are now included. Note that the video is from an early testing phase without the solar panel (later ones appear too large to upload).

Robot with solar panel and sensors as per final target (note students to design own solar panel mounts + IR sensor mounts - these were my test ones for proof of concept)

Solar panel removed to show the insides + solar panel mounts in more detail

Top of chassis removed to show more detail of insides

Example of the proof of concept solar panel asymmetric mount - see student presentations for their solutions.

Example of testing the robot to check it was feasible to program to follow a line - with analogue sensors.

5. I’ve posted the STL of the standardised chassis (with friction fit lid) to the Creality Cloud in case anyone is interested and/ or wants to use. I also include a pdf of the project briefing document below and some examples of the student submissions that have been received in this trial year - again comments and feedback welcome.

Posted Creality Cloud (STL files provided) -Engineering challenge chassis v3 (friction fit) + … From user5681115635 Engineering challenge chassis v3 (friction fit) + mounts | 3D models download | Creality Cloud

Further detail: Engineering Challenge - design and develop an autonomous solar powered line following robot

Last year saw a successful trial of the engineering project with four teams using the school’s 3D printer to produce the chassis’ and print the students designed parts – solar panel mounts + their design for mount of IR sensors. They learned lots along the way, with lots of trial and improvement, and developed a range of key engineering and team working skills.

For a little more context please review the attachments provided – you’re welcome to use but please do include me as a reference on this. I’d also welcome any thoughts, feedback or development suggestions.

The whole project has come about as a response to my current school having no Design and Technology department, but a strong STEM cohort of students. Many of these were applying to University or for apprenticeships to study Engineering or practical science degrees, but the lack of practical experience available through meant they were struggling to get through the application process. The engineering challenge was an effort to address this practical skills gap.

Examples of student produced materials:

Engineering challenge - Project Charter student example.pdf (297.8 KB)

Engineering challenge - Student project presentation example 1.pdf (1.2 MB)

Engineering challenge - Student project presentation example 2.pdf (1.2 MB)

Project briefing document - Challenge 1 v2 Y12 Jan 24.pdf (264.4 KB)