instructables

Project-Based Learning: How to Engineer a Race Team and Prototype Car

by blilly245

Students:
Welcome to this exciting project-based learning Instructable, where you'll have the opportunity to unleash your
creativity, teamwork, and problem-solving skills! In this hands-on project, you'll dive into the world of race car
engineering as you create your very own race team and design a prototype car. Get ready to embark on a thrilling
journey that combines branding, budgeting, circuits, simple machines, prototyping, and 3D printing.
Throughout this project, you'll take on the roles of team managers, engineers, and designers as you navigate the exciting
challenges of creating a winning race car. From brainstorming ideas and crafting a compelling team brand to designing
and building a functional prototype, you'll experience the full spectrum of the engineering process.
Take a look at the design challenge and rules for your race team's car
Rules and Build Regulations

For Teachers:
The motivation behind the Project:
With ten years of experience in teaching Science, Technology, Engineering, and Mathematics (STEM) at I.S. 98 in Brooklyn
N.Y., I have dedicated my career to inspiring young minds and fostering a love for hands-on learning. After years of
classroom experience and observing the ever-evolving landscape of education, I recognized the importance of project-
based learning in nurturing students' critical thinking, problem-solving, and teamwork skills. Understanding that
traditional textbook-based approaches often fall short of truly engaging students and preparing them for the challenges
of the future.
Motivated to make a di erence and provide an unforgettable learning experience, this project was developed ve years
ago. Since then, it has proven to be a remarkable journey for countless students, sparking their curiosity, igniting their
creativity, and instilling a lifelong love for STEM. By combining various elements such as branding, budgeting,
prototyping, and design, this project aims to provide a comprehensive and immersive experience that mirrors the
challenges and excitement of the professional world.
This project aspires to inspire the next generation of engineers, designers, and innovators, equipping them with the
essential skills needed to thrive in a technology-driven society. By engaging in hands-on activities, collaborating with
peers, and applying scienti c principles to practical challenges, students will develop critical skills, foster a growth
mindset, and gain the con dence to tackle complex problems.
Join us on this incredible journey as we dive into the world of race teams, branding, budgeting, prototyping, and design.
Let's embark on a path of exploration, discovery, and creativity, as we unleash our imaginations and unlock our potential
as future STEM leaders. Get ready to create, innovate, and make your mark in this exciting project-based learning
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experience.
NGSS Standards Addressed:
Engineering Design
MS-ETS1-1. De ne the criteria and constraints of a design problem with su cient precision to ensure a successful
solution, taking into account relevant scienti c principles and potential impacts on people and the natural environment
that may limit possible solutions.
MS-ETS1-2. Evaluate competing design solutions using a systematic process to determine how well they meet the
criteria and constraints of the problem.
MS-ETS1-3. Analyze data from tests to determine similarities and di erences among several design solutions to identify
the best characteristics of each that can be combined into a new solution to better meet the criteria for success.
MS-ETS1-4. Develop a model to generate data for iterative testing and modi cation of a proposed object, tool, or process
such that an optimal design can be achieved.
Physical Science (Circuits/Forces and Interactions):
MS-PS2-3: Ask questions about data to determine the factors that a ect the strength of electric and magnetic forces.
Supplies:

1. Foam boards (for constructing the prototype car)

2. 3V-9V hobby motors
3. Wires and connectors (for electrical connections)
4. Batteries and battery holders
5. Switches
6. Wheels
7. Axles
8. Straws (for axle holders)
9. Pulleys
10. Rubberbands (for drive belts)
11. Optional Hop-Up Parts (assortment of wheels, better motors, bearings for axles, metal axles, etc).
12. Stopwatches
13. Various crafting materials (e.g., markers, stickers, tape) for branding and decorating the car
14. Computer to access Tinkercad or Fusion 360 from the browser for designing the car chassis
15. 3D printer or access to a 3D printing service to print the car chassis
16. Tools (e.g., scissors, utility knife, ruler, wire cutters, hot glue, soldering iron) for construction and assembly
17. Laser Photogate for timing - (Not necessary but increases accuracy)

Please note that this list is a general suggestion, and you may need to adapt it based on your speci c design
requirements and the availability of materials.
**Credit** Image of Eudax Motor Kit currently available on Amazon
Kit with motors, battery pack, switches, wheels, pulleys, drive belts, etc - https://a.co/d/6qoMhcp
Foam Board for chassis prototype - https://a.co/d/2S2z7w0

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Step 1: Building Your Race Team

Students:
Your rst task will be to establish your race team by choosing a team name, logo, and team members. Collaborate with
your teammates to brainstorm creative ideas that re ect the spirit of your team and create a strong brand identity.
1. Building a race team involves more than just creating a car—it's about establishing a strong identity that
represents your team's spirit and values. Start by gathering your team members and brainstorming ideas
for your team's name, mission, and values. Discuss what qualities and characteristics you want your team
to embody, such as speed, innovation, or teamwork.
2. Once you have a clear vision for your team, it's time to design a logo that visually represents your brand.
The logo will serve as a symbol that distinguishes your team and creates a visual connection with your
audience. Consider the following tips for logo design:
3. Simplicity: Aim for a simple and clean design that is easily recognizable and memorable. Avoid excessive
complexity or intricate details that may make it di cult to reproduce the logo in di erent sizes or
formats.
4. Symbolism: Think about incorporating symbols or elements that relate to racing or your team's identity.
This could include imagery of cars, checkered ags, speed lines, or dynamic shapes.
5. Color palette: Choose a color palette that re ects your team's personality and aligns with your brand.
Consider using bold and vibrant colors that grab attention and evoke energy and excitement.
6. Typography: Select a font or typography style that complements your logo design and enhances its
overall aesthetics. Experiment with di erent fonts to nd the one that best represents your team's
character.
7. Originality: Strive for originality in your logo design, avoiding similarities to existing logos or trademarked
designs. Create something unique that stands out and captures the essence of your team.
8. Assign a team member or a group to take the lead in designing the logo. Provide them with the necessary
design tools such as graphic design software or even paper and pencils for sketching ideas. Encourage
collaboration and feedback from the entire team to ensure that everyone's ideas are considered.
9. Once your logo design is complete, present it to the team for feedback and re nement. Allow for open
discussions and revisions to ensure that the nal logo truly represents your team's identity and resonates
with everyone involved.
10. Remember to document the design process and keep digital copies of your logo in various formats (e.g.,
JPEG, PNG, vector le) for future use in promotional materials, team uniforms, and any other branding
initiatives.

By building a strong race team and designing a compelling logo, you will not only create a recognizable identity but also
foster team cohesion and pride. Your logo will serve as a visual representation of your team's hard work and dedication
throughout the project.

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Step 2: Researching Parts and Budgeting

Students:
1. Once your race team is established and you have de ned your team's brand identity, it's time to research
and select the parts you'll need for your race car. This step involves exploring di erent components such
as motors, wheels, gears, and other accessories that are suitable for your prototype car.
2. Divide your team into smaller groups, each responsible for researching a speci c component. For
example, one group can focus on motors, another on wheels, and so on. Encourage each group to nd
multiple options and compare them based on factors such as performance, price, durability, and
compatibility with your design.
3. As you gather information about di erent parts, keep track of their costs. Create a spreadsheet or
budgeting tool where you can list the parts, their prices, and any additional expenses associated with
them (e.g., batteries, connectors).
4. Calculate the total cost of the parts for your race car. Consider factors such as the quantity of each part
required for the car. This will help you establish a budget for your team and ensure that your expenses
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 align with your available resources.
5. Discuss and make decisions as a team based on your research and budget. Determine which parts
provide the best balance of performance and cost-e ectiveness for your race car. Keep in mind that
staying within budget while maintaining quality is an important aspect of engineering and project
management.
6. Re ect on your budgeting process and discuss any trade-o s you had to make. Consider how your
choices may impact the overall performance and competitiveness of your race car. This re ection will help
you make informed decisions throughout the project and develop critical thinking skills related to
resource allocation and nancial management.

By researching parts and calculating the cost or budget for your team, you'll gain valuable skills in researching,
budgeting, and making informed decisions. Remember to document your ndings and keep track of your expenses as
you progress through the project.

Teachers:
Each team should start out with a speci c amount of money in their budget. Additionally, you may want to create jobs in
your classroom and assign a "salary" to teams. This allows that teams to assist with setting up and cleaning up while also
seeing the bene t to their team's bank account. You can also create challenges that if completed are rewarded with
additional money to use to buy more parts to build a more powerful race car.
For a list of team challenges use the following link: Team Challenges

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Step 3: Prototyping

Students:
Now it's time to bring your race car to life! Using 3V hobby motors and foam board, you'll design and build a functional
prototype that showcases your engineering prowess. Through hands-on experimentation and testing, you'll re ne your
design to achieve optimal performance. Measure and record data to evaluate the e ectiveness of your prototype and
make informed decisions for improvements. As you build keep an eye on your progress and see which challenges you
might be able to check o . For a list of team challenges use the following link: Team Challenges
1. The prototyping stage is a crucial step in the process of creating your race car. It involves constructing a
functional prototype using hobby motors and foam board to test and re ne your design. Prototyping
allows you to experiment with di erent con gurations, make adjustments, and identify any issues before
moving forward with the nal design.
2. Start by gathering the necessary materials, including foam board, hobby motors, wires, connectors,
batteries, and switches. Ensure that you have the appropriate tools such as scissors, rulers, and assistance
for utility knives, and hot glue guns for construction.
3. Begin by designing the body of your race car on the foam board. Use a pencil to sketch out the shape and
dimensions of the car chassis. Consider the size of the motors, battery holder, and other components.
Once you have a clear design, carefully cut out the pieces using scissors or a utility knife with assistance
from an adult if needed.
4. Next, create holes in the foam board where the pulley and drive belt for the motor and axle will be
inserted. With assistance, measure the diameter of the pulleys and use a sharp utility knife to cut holes at
appropriate locations. Make sure the hole is sized correctly to ensure room for the pulley clearance and
drive belt.

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 5. To hold the axles in place, you can use straws as axle holders. Cut the straws into smaller sections that
match the width of your car chassis. Glue the straws onto the foam chassis, and ensure they are straight
on the foam board. The straighter they are the straighter your car will drive down the track. *TIP* Be sure
not to glue the axle to the axle holder (straws). This would prevent the axle from being able to
turn, therefore acting like a parking brake.
6. Attach the pulley and wheels to the end of the axles. Be sure to glue or tape them on so that they rotate
with the axle as it turns. If not attached to the axle it will spin inside the wheel or pulley and the car will
not move.
7. Attach the hobby motors to the foam board using hot glue or another adhesive. Apply a small amount of
glue to the bottom of each motor and press them rmly onto the designated spots. Make sure they are
aligned properly and parallel to each other to ensure smooth movement.
8. Connect the motors to the battery holder using wires and connectors. Strip the ends of the wires and
twist them together with the corresponding wires from the motors. Use electrical tape or soldering, if
necessary, to secure the connections. Attach the battery holder to the foam board using hot glue or other
adhesive.
9. Once all the components are in place, insert the batteries into the holder and test the functionality of
your prototype. Observe how the motors operate and make any necessary adjustments to ensure proper
alignment and movement.
10. Throughout the prototyping stage, take measurements and record data related to the performance of
your car. This information will be valuable for evaluating and re ning your design later on.

By prototyping with hobby motors and foam board, you'll be able to test and ne-tune your race car design, identify any
potential issues, and make necessary adjustments before moving on to the nal stages of the project. Remember to take
your time and be creative in nding solutions during this phase.

Teachers:
You can expand the prototyping stage to include lessons about circuits, wiring diagrams, simple machines with
mechanical advantage/gear ratios, and more. Tinkercad can be used to model circuits as well as wiring diagrams in the
"Circuits" feature. As teams build remind teams to check their progress and see which challenges they may have
completed to unlock additional funds to improve their car.
For a list of team challenges use the following link: Team Challenges

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Step 4: Designing the Car Chassis in Tinkercad

Students:
Once you have successfully tested and measured your prototype, it's time to take your design to the next level. Utilizing
the power of 3D printing and Tinkercad, you'll design a custom car chassis that will give your race car a competitive edge.
Dive into the world of computer-aided design (CAD) as you re ne your design, ensuring both aesthetics and
functionality.
1. Tinkercad is a user-friendly online 3D design tool that allows you to create digital models. In this step, you
will use Tinkercad to design the car chassis, which will be 3D printed for the nal assembly of your race
car.
2. Start by creating an account on Tinkercad if you haven't already done so. Once you're logged in, you'll be
greeted with a blank canvas where you can start your design.
3. Familiarize yourself with the Tinkercad workspace. It consists of di erent tools and features, such as shape
generators, basic shapes, and manipulation tools on the right side, and a workplane in the center where
you'll be designing your car chassis.
4. Now it's time to design the base of the car chassis. Use the basic shapes available in Tinkercad, such as
boxes or cylinders, to create the main structure. Click on the desired shape, drag it onto the workplane,
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 and resize it by dragging its handles.
5. Combine and manipulate the shapes to form the base of your car chassis. Use the alignment and
grouping tools in Tinkercad to position and join the shapes together. Experiment with di erent
con gurations and dimensions to achieve the desired design.
6. Add additional features and details to your car chassis, such as cutouts for the motors, spaces for the
axles, bearings, or any aerodynamic elements you want to incorporate. You can use various Tinkercad
tools like the hole tool, and shape generators, or even import custom shapes if needed.
7. As you design, consider the dimensions and compatibility of your car chassis with the existing
components, such as the motors, wheels, and battery holder. Make sure there is enough space and
proper alignment for these components to t in the nal assembly.
8. Once you are satis ed with your car chassis design, review it from di erent angles using the navigation
tools in Tinkercad. Make any necessary adjustments or re nements to ensure a well-balanced and
functional design. Keep in mind as you design that print time is a factor in the price of your car. The longer
it takes the print the more of your budget will be used. Try to design in a way that simpli es the design
and print time to be the most e cient.
9. When your car chassis design is complete, you can export it as an STL le, which is a standard le format
for 3D printing. Save the STL le to your computer or a removable storage device, as you will need it for
the next step of the project.

By designing the car chassis in Tinkercad, you can create a digital model that represents the structure of your race car.
Tinkercad o ers a user-friendly interface and a range of design tools to help you bring your car chassis to life. Remember
to be creative and take your time to re ne the design until you are satis ed with the nal result.

Teachers:
Creating a Tinkercad classroom and adding your students is incredibly simple and can be used with Google Classroom.
This allows you to view, duplicate, and download all of the student-created designs in one easy-to-use location. If you
have students that are already familiar with Tinkercad you may consider signing up for an educator license for Fusion 360
and adding those students. Fusion 360 will provide a steeper learning curve but additional features in customizing their
CAD chassis designs. There are various easy-to-follow tutorials available for both Tinkercad and Fusion 360.

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https://www.instructables.comhttps://www.tinkercad.com/things/6ykdNfdZHDX

https://www.instructables.comhttps://www.tinkercad.com/things/lLU5nkiyolG

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https://www.instructables.comhttps://www.tinkercad.com/things/6neSprkU13M

Step 5: Assembling and Testing

Students:
With your 3D-printed car chassis in hand, it's time to assemble the nal race car. Follow the provided instructions and
utilize your problem-solving skills to bring together all the components. Once assembled, it's time for the most exciting
part - testing your creation! Prepare for some thrilling races and measure the performance of your race car against your
team's objectives.

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 1. Once you have 3D printed the car chassis and all the necessary components are ready, it's time to
assemble the car and test its performance. This step will help you evaluate how well your design
functions and identify areas for improvement.
2. Begin by gathering all the printed parts, motors, wheels, axles, and other components needed for the
assembly. Make sure you have the necessary tools, and any adhesives required for securing parts
together.
3. Start assembling the car by attaching the hobby motor to the designated area in the car chassis. Ensure
that the motors are properly aligned and rmly secured in place.
4. Install the axles into the axle holders on the car chassis. If you used straws as axle holders during the
prototyping stage, slide the axles into the straws. Ensure that the axles are straight and rotate freely
without any friction.
5. Mount the wheels onto the axles. Depending on your design, you may need to use additional
components such as washers or spacers to ensure proper alignment and stability. Make sure the wheels
are securely attached and can rotate smoothly.
6. Connect the wiring from the motors to the appropriate terminals on the battery holder or power source.
Double-check the connections to ensure they are secure and that the polarity is correct. Use tape,
soldering, or connectors to ensure reliable electrical connections.
7. Before testing, ensure that the batteries are fully charged or have su cient power. Insert the batteries
into the battery holder and switch on any additional components like switches or LED lights, if applicable.
8. Find a suitable location for testing your car, such as a smooth surface table, hallway, or race track. Ensure
that the area is clear of obstacles and provides enough space for the car to move freely.
9. Turn on the power source and observe the car's performance. Note how fast it moves, how straight it
drives, and any vibrations or issues you observe. Encourage team members to record data during the
testing process.
10. Collect data that will help you evaluate the car's performance and guide modi cations to the design.
Useful data to collect includes speed measurements using a stopwatch or measuring distance covered
within a speci c time frame. You can also record any observations regarding stability or potential areas for
improvement. For a copy of the team datasheet use the following link: Track Datasheet
11. Analyze the collected data and discuss it as a team. Identify any areas where the car's performance did
not meet your expectations or any design aws that need to be addressed. Consider how modi cations
to the design, such as adjusting weight distribution, changing wheel size, or improving aerodynamics,
could improve performance.
12. Based on the data analysis, make informed decisions about the necessary modi cations to the car design.
Discuss potential design changes and collaborate as a team to implement these modi cations e ectively.
13. If needed go back to your 3d chassis design and make modi cations and repeat the testing and data
collection steps.

By assembling and testing the car, you will gain valuable insights into its performance and identify areas for design
optimization. Collecting data and analyzing it critically will help you make informed decisions about necessary
modi cations. Remember to document your ndings and use them to drive iterative improvements in your car design.
Teachers:
The track data sheet is a great way to collect information for the team and create discussions about performance and
observations. Stress to the students the power of the data and how it helps the team set goals for future challenges and
designs.

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Step 6: Assessing the Team

Students:
For a list of team challenges use the following link: Team Challenges
Data Collection Sheet: This sheet is a tool for teams to record and analyze data during the testing phase of their car
design. It includes various parameters and metrics that can be measured to assess the performance of the car. The sheet
serves as a guide for students to systematically collect and document their observations, enabling them to make
informed decisions about modi cations to their design. This sheet can also be used as evidence for completing speci c
challenges.
Team Usage:
1. Recording Data: Teams can use the data collection sheet to record measurements such as speed, distance
traveled, and time taken during test runs of their car. They can note the speci c settings or con gurations
used for each trial.
2. Analysis and Comparison: Teams can use the collected data to analyze the performance of their car under
di erent conditions. They can identify trends, patterns, and outliers, and discuss how di erent factors
might have in uenced the results.
3. Re ection and Decision-making: The data collection sheet prompts teams to re ect on their ndings and
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 consider modi cations to improve their car's performance. By analyzing the data, teams can identify
areas where adjustments or enhancements can be made to enhance speed, stability, or e ciency.

Teacher Usage:
1. Formative Assessment: The teacher can review the data collection sheets to assess students'
understanding of the project objectives and their ability to collect and interpret data. By examining the
recorded measurements, the teacher can identify areas where students might need additional support or
guidance.
2. Classroom Discussion: The data collection sheets can be used as a basis for classroom discussions. The
teacher can facilitate discussions where teams share their ndings, compare results, and explain the
rationale behind their design choices. This promotes collaboration, critical thinking, and a deeper
understanding of the scienti c and engineering concepts at play.
3. Feedback and Support: Based on the data collected, the teacher can provide targeted feedback to
individual teams or the entire class. The teacher can o er suggestions for improvements, highlight areas
of success, and guide students in further re ning their designs.

Overall, the data collection sheet serves as a valuable tool for both teams and the teacher. It enables teams to track their
progress, analyze their results, and make data-driven decisions. Simultaneously, it allows the teacher to monitor student
progress, provide formative feedback, and facilitate discussions that deepen students' understanding of the project's
scienti c and engineering principles.
For a copy of a weekly goal-setting sheet use the following link: Goal Setting Sheet
For a copy of a self-re ection sheet use the following link: Self-Re ection Sheet

Teachers:
Proof of Mastery:
Teams can use their Logo Branding, Prototype Car, 3D Printed Car, Portfolio of designs, and data collected to demonstrate
mastery. This could be done as a presentation, digital portfolio, or video.

Additionally, formative assessment can be done through the use of various challenges. Consider having the student
teams create and provide feedback on challenges they might want to add to the list.
Using rewards from the Team Challenges helps to get teams a target to focus on and iterate towards. If teams receive
rewards from racing and beating other teams then those teams will be the only teams that increase their budget and
gain an advantage. Racing should be done in the spirit of competition. These challenges also serve as a form of
assessment.

Additional Examples of Challenges and Awards can include:

1. Budgeting Challenge: Teams are given a xed budget to "purchase" parts from their teacher. The
challenge is to create a detailed budget plan, allocating funds to di erent components based on their
cost and importance. Teams must justify their budget choices, demonstrating their understanding of
cost-e ectiveness and prioritization.
2. Design Challenge: Teams are tasked with designing a car chassis that meets speci c criteria, such as
minimum weight, maximum stability, or optimal aerodynamics. They must apply their knowledge of
engineering principles and use their creativity to come up with an innovative and functional design.

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 3. Speed Challenge: Teams compete to build the fastest car within their budget. They need to optimize their
design, select appropriate motors and wheels, and ne-tune their car's performance to achieve the
highest speed possible. The team with the fastest car wins the challenge.
4. Precision Challenge: Teams are challenged to build a car that can travel in a straight line with maximum
precision. They must focus on wheel alignment, weight distribution, and minimizing friction to ensure the
car stays on track without veering o course.
5. Innovation Challenge: Teams are encouraged to incorporate unique features or modi cations into their
car design. This challenge rewards teams for their creativity, out-of-the-box thinking, and ability to apply
scienti c concepts to improve their car's performance or aesthetics.
6. Durability Challenge: Teams must build a car that can withstand rigorous testing and racing without
major failures or damage. The challenge focuses on selecting robust materials, ensuring proper
reinforcement, and evaluating the car's ability to withstand di erent forces and conditions.
7. Data Analysis Challenge: Teams are required to collect and analyze data during testing, such as speed
measurements, distance covered, or acceleration rates. They must interpret the data, draw conclusions,
and make adjustments to their design based on their analysis to optimize performance.
8. Presentation Challenge: Teams present their car design, budget plan, and modi cations to a panel of
judges or the class. They must e ectively communicate their design choices, explain the science behind
their decisions, and showcase their understanding of the engineering principles involved.
9. Teamwork Challenge: Teams are assessed on their ability to collaborate, delegate tasks, and work
e ectively as a team. This challenge emphasizes teamwork, communication, and problem-solving skills,
encouraging students to learn from one another and leverage each other's strengths.
10. Re ection Challenge: Teams re ect on their design and building process, identifying successes,
challenges, and lessons learned. They present a written or oral re ection highlighting their growth, areas
of improvement, and how they would approach the project di erently in the future.

These challenges not only assess the teams' mastery of the project but also foster engagement, competition, and critical
thinking. By unlocking rewards for completing challenges, teams are motivated to push their boundaries, think critically,
and strive for excellence in their team's race car-building endeavor.

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Thanks for sharing your lesson!

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