The Challenge

UBC Supermileage competition vehicle uses a two part shell design. A connection method between the top and bottom half of the shell is required. This connection method needs to ensure all gaps between two parts are eliminated even when the shell deforms.

Designing and Manufacturing

The cross-shaped extrusion is designed to account for lateral movement in the shell. The hollowed rectangle shape is used to fit magnets which is connecting the top and bottom shells.

Certain areas of the part are extruded to remove excess material without effecting the performance.

The end product was created through 3D printing.