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Authorized Client Case Study

High-Performance
Steering Wheel Prototype

Engineering-grade prototype with integrated electronics, carbon fiber composite construction, and precision CNC machined aluminum mounting hub. Delivered 10 units in 7 days.

Project Overview

Industry
Automotive Racing
Material
Al 7075 / Rubber
Process
Overmolding & CNC
Finish
Matte Anodized
Lead Time
7 Days
Volume
10 Units

The Challenge

"Our client needed to perform extensive ergonomic testing and electronic integration validation on their new racing steering wheel before committing to expensive production tooling."

Critical Requirements

  • Real feel grips: The rubber overmolding needed to simulate the final shore hardness perfectly for accurate driver feedback.
  • Structural rigidity: The core aluminum hub had to withstand full torque testing on a racing simulator.
  • Tight assembly tolerances: Precise cutouts and button housings for seamless electronics integration.

Our Execution

We utilized a hybrid manufacturing approach, combining 5-axis CNC machining with vacuum casting to achieve production-like quality rapidly.

1

Structural CNC Hub

The core mounting hub and structural frame were CNC machined from 7075-T6 billet aluminum, providing the rigid backbone necessary for torque testing.

2

Soft-Touch Vacuum Casting

We 3D printed a master pattern to create silicone molds. A specific Shore A 60 urethane was then cast directly onto the machined frame to create perfectly bonded, seamless ergonomic grips.

3

Premium Finishing

The exposed aluminum sections received a soft bead blast and matte black anodization for a glare-free, professional racing aesthetic.

Technical Highlights

  • 5-Axis CNC Machining
  • Vacuum Casting (Urethane)
  • Overmolding Bonding
  • Hard Anodizing (Type III)

Have a Complex Assembly?

We specialize in multi-process manufacturing and overmolding prototypes.

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Evidence basis

Engineering evidence record

Multi-process steering wheel prototype record. This public case summary is based on anonymized RFQ notes, engineering review, inspection planning, and packing handoff records; customer-sensitive details removed.

Last reviewed: 2026-07-01
Customer industry
Automotive interior prototype development; customer-sensitive details removed.
Part use
Ergonomic and assembly validation sample for steering wheel concept review.
Quantity
Small prototype run for design validation and presentation review.
Material
CNC-machined metal hub plus overmolded / cast prototype grip material confirmed by RFQ.
Process
CNC machining, surface preparation, soft-tooling / vacuum casting, trimming, and fit review.
Critical dimensions / tolerances
Hub interface, spoke alignment, grip section, assembly datum, and visible seam control.
Surface finish
Grip texture, seam appearance, color target, and visible trim edges reviewed against reference samples.
Max manufacturing risk
Multi-material shrinkage and bonding alignment can affect grip feel and hub fit.
DFM before / after
Before: ergonomic surface and hub datum requirements were mixed in one model. After: hard interface, soft grip, seam line, and assembly datums were separated for manufacturing review.
Inspection method
Dimensional check for hard interfaces plus visual / tactile review for soft-touch surfaces and seams.
Shipping documents
Commercial invoice, packing list, packaging photos, and agreed inspection records when scoped.
Lead time / result
Prototype route supported ergonomic review and fit validation; final capability depends on approved material and tooling route.
Customer authorization
Representative case shared with customer-sensitive details removed; public photo use is limited to approved imagery.
Evidence basis
Based on anonymized RFQ notes, DFM review, inspection planning, and packing handoff records. Last reviewed: 2026-07-01.
Quote boundary: This case does not imply default CMM, FAI, certification, regulatory approval, or production readiness. Inspection method, shipping documents, customer authorization, and documentation package must be agreed during RFQ.
This case study is shared as a representative manufacturing example with customer-sensitive details removed. All intellectual property rights remain with the original owner.