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.
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.
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.
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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