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I served as the mechanical design and manufacturing lead for a dual-motor, four-sensor line-following robot that could autonomously navigate a track using closed-loop control. My main focus was turning our concept into a cohesive and manufacturable system — one that balanced precision, reliability, and creativity. The final design was compact, stable, and visually distinctive, completing the course in just 36 seconds with consistent tracking performance.
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I assisted in developing specifications for the acrylic chassis, helping determine component spacing, sensor positioning, and access clearances to make assembly and maintenance efficient.
From there, I led the fabrication of several custom mechanical parts, including a 3D-printed PLA enclosure that housed the Arduino and motor shield while doubling as a structural mount for the rear caster wheel.
I also designed and fabricated the sensor mounting system, iterating to find the optimal spacing and height for accurate line detection. The final design used press-fit slots that made sensor replacement simple and kept the car serviceable during testing.
To tie it all together, I helped assist in manufacturing the laser-cut fiberboard side panels that gave the robot its playful apple-car aesthetic inspired by Richard Scarry’s Lowly Worm’s Apple Car. The team used raster engraving to capture surface details and maintain a clean, characterful finish. This project strengthened my understanding of design for manufacturability and multi-material integration, teaching me how weight distribution, fit tolerances, and modular design all influence performance. It also reminded me that good engineering can be both functional and expressive — combining creative design with solid mechanical execution.
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