High-Precision 3D Modeling Creates Valuable Shortcut for Innovative Off-road Vehicle
DaCar and Objet have teamed up for an
ambitious goal of developing a unique and revolutionary high-adrenaline
desert vehicle that can be driven and supported by a lean team. What
they developed is truly unique and quite possibly the future of 2 x 4
rally off-road vehicles.
When it comes to off-road vehicles, everyone is looking for new ways to go faster while still maintaining high navigational capabilities and precision. Engine design and materials, fuel formula, body aerodynamics and other elements all come together to create an experience which is not only exciting, but also a vehicle which meets the tough demands of the terrain. In this world where human creativity and the laws of physics are the only limits on achievement, careful design and pre-production testing are absolutely crucial not just for success but also for safety.
The three-person DaCar team, which wants to introduce an entirely original FIA-certified 2 x 4 rally off-road vehicle, is intimately familiar with all of these issues. “Our vision is to build a high-resolution vehicle where a crew of three eliminates the need for a large and expensive support team,” they say. With this ambitious goal of developing a high-adrenaline desert vehicle that can be driven and supported by a lean team, they knew they would not be able to do it alone. When the team members approached Objet Geometries’ corporate office, it jumped at the chance to be involved with such an exciting venture.
The Design Team
The pool of expertise formed by the DaCar team includes architecture,
industrial design, automotive design, agricultural equipment
development and off-road vehicle construction. The team also has years
of experience in off-road competitions, having won first place in many.
These strengths, bolstered by the strengths of Objet, more than just
alleviate some of the budgetary issues, but also contribute vital
technical knowledge and equipment.
Objet worked closely with the DaCar team to provide the advanced modeling capabilities they needed to test their revolutionary ideas with maximum efficiency, accuracy and cost effectiveness.
Revolutionary Approach From the Start
In planning their all-new off-road race, the team has disregarded
design conventions that use organic lines. Instead, the design team is
using the strong, sharp lines of cutting and breaking, which has
resulted in a racier, more dynamic appearance. In the world of racing
and off-road vehicles, motorcycle design in particular expresses an
eruptive force, an absolute control of the vehicle that produces a
sense of hovering and excitement. Motorcycle design obeys one of two
main paradigms: the “full body,” which includes the various coverings,
and the “naked” look. The team has combined these two paradigms into a
single integrated version that will withstand the demands of the
terrain.
The DaCar team has also reduced shell complexity in order to minimize noise levels. This has been achieved by using two main shells: an upper one that protects the body’s center, and a lower one that protects the belly and sides. The layered design has produced a look of forward momentum and the balanced configuration of the shells gives the vehicle a look of stability and strength. The division of the shells is planned so as to enable quick and efficient dismantling during a race. The rear part rises sharply upwards to create storage space for wheels and additional equipment.
While most racing cars seat two crew members (a driver and a navigator), the DaCar is designed for three—a driver and two crew members. This improves navigational capacity as well as making maintenance and extrication more efficient.
The Results
The
result was unique. In contrast to most off-road vehicles, the DaCar has
a central motor and rear-wheel drive, which gives it a considerable
weight advantage while creating a light and durable vehicle at low
cost. The DaCar also has a high seat, which opens up a wide field of
vision. With the engine positioned in the center, most of the weight is
directed to the rear drive wheels. The light nose enables the vehicle
to glide over hollows and provides resistance against hard impacts.
The belly structure and seating arrangements are also unconventional: the narrow belly prevents the vehicle from getting stuck while crossing sand dunes, and as the belly contains the fuel tanks and the propulsion systems, the whole vehicle maintains a low center of gravity.
Objet’s ability to meet these requirements highlights its true versatility, accuracy and its well-earned reputation for paying strict attention to the smallest details. Every knob and lever in the vehicle’s interior, from the valves in its gears to the intricate steering wheel, comes together in a coalescence of hard and soft durable materials, some of which were coated and painted to create a true life-like off-road vehicle, which merges the boundaries between design, operation and business planning.
For the wheels, Objet’s TangoBlack material facilitated a real rubber-like feel while much of the vehicle’s body was produced from its Vero materials, which withstand bending and enhance visualization of details and edges. The FullCure family of proprietary acrylic-based photopolymer materials enabled the creation of highly accurate, finely detailed elements for maximum integration and variety.
“We’re harnessing all this diversity for the planning of a unique vehicle for serial production,” says the DaCar team, further elaborating Objet’s critical contribution to the process: “Using the Objet model, we created a superb study platform, which has resulted in optimum line production.”
Using Objet’s Eden 3-D Printing System, the DaCar team built a high-precision 1:8 model of the rally vehicle. While developing the structure and the exterior shells, the DaCar team could test shapes, proportions, colors, dialog between parts and their integration and assembly.
According to the team, “By intensive testing and continuously developing the model shells, we were able to ensure an optimal result and study the platform before going to production of the buggy.”
The Dacar team is now in the first production stages. The Objet team found it very interesting working with them on designing the new off-road racing vehicle and is excited to see the car in action.
For more information about Objet’s 3D modeling solutions, visit www.2objet.com.
