3D-Printed Truck

Assembly Design
AEM 390 class
Spring 16'
DUI GUYS Group Team Members:
Adams Stephen, Bracco Patric, Davis Elliott, Elliott Hayden,
Grenke Mark, Isaacs Brian, Johnson Cody, Jones Anthony,
Kimbler Matthew, Poynter Lucas, & Wright Martin.

Schedule of Events
Week of:

TASKS

4/4

Group Project Proposal Due

4/18

All Modelling CAD Files Due

4/25

Motion or Simulation Due

5/2

Report and Digital Copy of Presentation Due

5/2

Prototyping Due

5/9

Final Presentation

MS Project

Project Leader: Luke Poynter

As the group project leader- I was tasked with getting everything organized in
such a way that everyone knew what they were doing.
It took roughly 10 hours to get the model created so that everything worked
correctly together.
Once I got all the parts designed, and got the model ready, I then made prints
of all the parts so everyone would know the dimensions that they were to keep.
Something that wasn't taken into account which created some problems was
that the 3D printer doesnt print exact.
The holes were about .020 small, which made it hard to get the pins in that
held the parts together.
I used a drill to ream out the holes so the pins would fit in the holes better.

Luke Poynter
The model the class
created

The original model I

created.

Luke Poynter

Cody Johnson
Back hitch of the
truck. This is my part,
it is 6.75inches long
and it is used to haul
things from place to
place. I used a carbon
steel, heavy weight
material. Took me 1525min to make it
perfect and right.

Adam Isaacs
The 3D Printed Parts
My design emulates a fully
built Chevrolet V8 with design
cues from the 1960's

Had problems with the design

and the assembly.
But generally, it was a simple
design.

Adam Isaacs, con.

This shows all the pieces in a
exploded state.
I designed the block itself in
two pieces for ease of 3D
printing.

The parts I made were a valve

cover x2, head x2, blower x1,
left and right blockx1 each,
and an oil pan x1.

Adam Isaacs, con.

The 3D Printed Parts
This is before the parts being
assembled.
Had to ream the holes for the
connectors on all the parts.

Elliott Davis
Front axle

The problems we encountered during this process was trying to

make sure everything fit perfectly with the wheels and the frame.
Along with the wheels rotating, we also
worked with the steering of the wheels.

Elliott Davis

Tie Rod

Hub
Parts Used in Assembly File
and 3D Printed

Shaft

Matt Kimbler
Step Boards

Matt Kimbler
The step bars are practical for stepping into a higher vehicle with
less strain on the body.
A modern stylish grip pattern was designed to give foot traction on
the step area as well as adding aesthetics (logo of group name was
also implemented into the traction grip).
The round tubing would be made of metal coated with chrome,
and the traction step pad would be a hard textured plastic
polymer for superior grip.

Matt Kimbler- Expectations

The image I had in my head for design of the step bars was fully
satisfied by the 3D model.

After part was 3D printed, it looked really well and showed all the
details. It just lacked color because it was all white.
I was also satisfied with the overall look it had combined with
everyone else's part on the frame.

Travis Adams

Truck Seats

Travis Adams
Practical bench seating style with a modern center console added

Material used for seating was black leather for the console and
burgundy cloth for seating to resemble school colors
Built with multiple Solidworks tools learned in class, such as:
sketch, extrude, extrude cut, smart dimension, fillet, etc.
Problems encountered..
Ways to improve my design..

Anthony Jones

I created the front bumper, the first

design I created was too aggressive.

It didnt match the vintage of our

truck manufactured 50's.

The second design I created is the

one seen here to the right.

The goal was to make it more square

and to look like something that
would have been on a truck from
this time period.

Anthony Jones

Problems that I encountered:

I didnt make the pins initial for the

bumper to attach to the fame.

I measured from the top of the

bumper, instead of from the bottom.
Therefore my bumper was a few
inches shorter than what it should
have been.

Cutting the wheel wells out. Caused

paint to crack.

Anthony Jones

The most difficult part of painting

the truck was masking off the small
areas.

The gas cap, headlights, grill, and

chevy symbols.

The plan was to do a two-tone paint

job. White on the top and black on
the bottom. Ended up being all black
with chrome trim.

The bed was made from popsicle

sticks that were cut down to size.

Stained and clear to give a vintage

look.

Patric Bracco
Method

Problems

Contribution

-Getting Actual Tread on Tire

-Created the tire

-Fitting Tire onto assembly

-Originally made rim cover but the
tire had to be flipped to fit on
assembly

Mark Grenke
Rear Axle
The rear axle was made to rotate the rear tires
when the transmission turn the drivetrain.
The axle also supports the vehicle from hitting
the ground.

The boxed areas on the axle represent the axle

hanger U-bolts, that hold the axle in place on
the Leaf Springs.

Martin Wright

Final Assembly

Animated Assembly
In order to make the motion simulation rotary motors were
applied (rotating at 100 RPM) to all four wheels.
The main problem encountered was not being able to show how
the front two wheels were supposed to be able to steer.

Conclusions: problems encountered and how

they were solved.
Paint problem
-paint pins didnt show; solved by not using them.
-body paint cracked because of flex; problem wasnt solved by lack of time.

-masking tape was hard to get in small areas; solved by pre cutting strips of
tape.

Conclusions: problems encountered and how

they were solved.
Some parts had to be redone after they were 3D printed
Didnt line up to fit in place; solved by remaking parts or modifying the
existing ones.

didnt function to let car move; solved by remaking parts or modifying the
existing ones.

Future Enhancements
Introduce the project sooner. To give a more time when problems arise.
Use a rubric to gauge the amount of effort that was put in by individual
team members.
Use examples from previous classes to give students an example of what is
expected at the end of the project.