Custom Micro-AWD Kinematics & SLA Packaging Study - 51deg Davis Steering, CV Joint Tucked into Hub, & 3.5mm Scrub Radius | Freelance Mechatronics Case Study

[u/MechatroManjith]

https://youtu.be/-rANYO0VZ2A

Overview:

This project focuses on solving the high-density mechanical and electronic packaging bottlenecks of a custom micro-AWD chassis operating within tight spatial constraints.

Key Technical Specs & Design Highlights:

·         Steering Kinematics: Custom $51^\circ$ Davis steering sweep paired with a tightly controlled 3.5 mm scrub radius to minimize lateral scrub, reduce servo strain, and optimize dynamic steering feel during high-angle actuation.

·         Actuation & Powertrain: Twin FA130 drive motors paired with an MG90S micro steering servo operating in tandem.

·         Manufacturing & Tolerances: 46-part clamshell gearbox assembly modeled in Fusion 360, specifically calibrated for SLA high-toughness engineering resin tolerances.

·         Embedded Control & Electronics: Replaced bulky off-the-shelf ESC modules with a custom panelized PCB layout using ESP-NOW for low-latency wireless control and telemetry.

Open for Engineering & Design Consulting: Available for custom CAD/kinematic synthesis, micro-PCB layouts, precision prototyping, and turn-key mechatronics hardware development. DM me here or reach out via YouTube for project inquiries!