3D Printed RC Car
3D PrintingAdvancedGrade 7Grade 8Grade 9

3D Printed RC Car

A hands-on project focused on designing, printing, and assembling a functional RC car using 3D printed components and basic electronics.

120 min 10 steps
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What you'll learn

Design and print custom mechanical parts
Integrate electronics with 3D printed structures
Assemble a fully functional RC vehicle

Overview

This project challenges you to design and build a fully functional 3D printed RC car by combining mechanical design, CAD modeling, and electronics integration.

You will:

  • Design and assemble multiple custom parts
  • Replace off-the-shelf components with 3D printed alternatives
  • Explore how mechanical and electrical systems work together

This is a great project to strengthen your CAD skills, prototyping ability, and system thinking.

Project Video

Materials

📦 Materials

PLA or PETG Filament~200g
TPU Filament~100g

⚡ Electronics

Motor (457RE385)1
Speed Controller (DumboRC 10A ESC)1
Battery (7.4V 650mA LiPo)1
Receiver & Transmitter (X6FG)1 set
Servo (PS-1171MG)1

Build Steps

1Servo Installation
Step 1Step 1

Attach the servo to the mount using two 10mm screws. Adjust the bracket if your servo size differs from the PS-1171MG. Attach the servo arm securely using the original screw that came with the servo. Files needed: • servo mount.stl • servo arm.stl

💡 Tip: Make sure the servo is centered (at its neutral position) before attaching the arm — this ensures your steering will be straight when the transmitter stick is centered.
2Steering Arms
Step 2Step 2

Ensure all arms rotate freely before assembly. File any edges if needed to remove print artifacts. Attach both steering arms to the center arm loosely — do not overtighten yet. Connect the center arm to the servo arm using a 10mm screw. Files needed: • Steering arm.stl • center arm.stl

💡 Tip: Check that the steering arms move freely through the full range of motion before tightening.
⚠️ Warning: Do not overtighten the screws connecting the arms — they need to pivot freely.
3Front Wheels
Step 3

Insert bearings into the wheel hub parts — press them in firmly until flush. Pass a 30mm screw through the center of the hub, add a washer, then secure. Use a nylon locking nut to prevent the wheel from loosening during use. Files needed: • Wheel Bracket.stl • Hub.stl • Tyre.stl

💡 Tip: The TPU tyre should press-fit onto the wheel rim. Heat the tyre slightly with warm water if it is too stiff to fit.
⚠️ Warning: Ensure the bearing is fully seated before inserting the axle screw.
4Front Arm Assembly
Step 4

Check all parts fit smoothly and allow free movement before assembling. Attach: • Wishbones to the steering bracket using 22mm screws • Suspension piece in the correct orientation Files needed: • Front arm.stl • Front arm top.stl • Steering Bracket.stl • Suspension.stl

💡 Tip: Dry-fit all parts before inserting screws to make sure everything aligns correctly.
5Attach the Wheel
Step 5

Secure the front wheel to the steering bracket using 8mm screws. Ensure the wheel spins freely with no rubbing against the bracket or suspension arms.

💡 Tip: Spin the wheel by hand after attaching — it should rotate freely with no wobble or drag.
6Complete the Front Arms
Step 6Step 6

Ensure smooth movement across all joints before finalising. Attach: • Suspension using 16mm screws • Top wishbones using 30mm screws • Base connections using 22mm and 40mm screws File needed: • Front arm Bracket.stl

💡 Tip: The front arm assembly should have a small amount of vertical travel (suspension movement). This is normal and intended.
7Finalize Steering
Step 7Step 7Step 7

Mount the servo onto the chassis base using 10mm screws. Connect the steering arms to the wheel connector, allowing a small amount of vertical movement for suspension travel. Check that turning the servo arm left and right steers both front wheels simultaneously and symmetrically.

💡 Tip: With the servo powered and at center, both wheels should point straight ahead.
8Driver Arm (Drive Shaft)
Step 8

Insert the steel pins into both halves of the drive shaft connector. Ensure a tight, secure fit — the pins should not be loose. If they are, add a small drop of CA glue. Files needed: • Driver arm.stl • Pin.stl

💡 Tip: The drive shaft transfers power from the gearbox to the rear wheels. A loose pin here will cause slipping under load.
9Small Gear Assembly
Step 9

Cut a 3mm steel rod to exactly 23mm in length. Slide the small bevel gear onto the rod and secure it firmly using the M2.5 grub screw. Files needed: • Inner Driver Gear.stl • Back gearbox connector.stl • Long washer.stl

💡 Tip: Use a ruler and sharp cutters to get an accurate 23mm cut.
⚠️ Warning: Tighten the grub screw firmly — a loose gear will slip and prevent the car from driving.
10Large Gear Assembly
Step 10Step 10

Press a bearing into the center of the large bevel gear until fully seated. Attach the gear arm to the assembly using 8mm screws. Carefully align both bevel gears so they mesh smoothly. Files needed: • Back gearbox connector.stl • Gear Arm.stl • Large gear.stl • Small Gear.stl

💡 Tip: Rotate the gears by hand after assembly — they should turn smoothly with light resistance.
⚠️ Warning: Gear tooth alignment is critical. Even 1mm of misalignment can cause binding or stripping under load.

Reflection Questions

1.What part of the build was the most challenging, and how did you solve it?
2.Which component required the most adjustment or reprinting, and why?
3.How would you improve the design in your next version?

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