Manual Transmission System

I pursued this project out of a strong interest in the inner workings of cars. Throughout the process, I faced several challenges, primarily related to size constraints and tight tolerances. The final model features two gears, a synchronizer, and a motor for power.

Since many components of this model were 3D printed using PLA filament, I had to do extensive rapid prototyping to ensure precise tolerances. This was essential to guarantee that all the components—gears, shifters, shafts—had enough space to function properly.

Transmission is on the left, rotary engine on the right

In this project, I primarily utilized 3D printing to fabricate most of the components, which allowed for quick iterations and detailed customization. However, to achieve tighter tolerances and create more durable, precise, and load-bearing structures, I also incorporated some manual machining techniques, including lathing and welding. This combination of additive and subtractive methods allowed me to balance precision with strength in critical areas of the model.

This project involved dozens of interconnected components that had to work seamlessly as a single system. One of the main challenges was designing a mechanism where the gears remained disengaged from the shafts until the synchronizer for that gear was activated. Achieving this required careful attention to tolerances and spacing to ensure smooth operation without interference.

Before this project, I didn’t know much about how cars actually worked, but it ended up being one of my all-time favorites. It taught me a ton about automotive systems and really sparked my interest in exploring other parts of how vehicles function.

Video of Model Working