Ergo Steering Wheel

Project Overview:
This steering wheel redesign focuses on enhancing ergonomics, improving driver comfort, increasing visibility, and ensuring structural and functional integrity.

Identified Issues in Previous Model:

1. Frame Thickness & Material - The aluminum frame was too thin and fully tubular, making it uncomfortable for prolonged use.

2. Handle Reachability - Interior handles were positioned too far apart, causing strain and reducing control efficiency.

3. Button Security - Buttons were not secured properly and were prone to coming loose during competition, posing a safety and function risk.

4. Visibility & Shape - The circular silhouette of the frame obstructed visibility of the dashboard and driving path, limiting situational awareness and the best possible performance during the race.

Redesign Improvements:

1. Optimized Frame Shape

   • Transitioned from a circular design to a squircle (stadium-shaped) outline commonly seen in motorsports (e.g., Formula 1).

   • This enhances visibility and expands the driver’s range of steering motion.

2. Enhanced Handle Ergonomics

   • Integrated custom handle cutouts that conform to natural hand positioning and finger curling for improved grip and ease of use.

   • Added padding and contoured shaping to improve overall tangibility and driver comfort.

     • In the first prototype, the padding was found to be misaligned with the cutouts. In turn, new padding was creating to properly conform to cutouts and driver hand shapes and curls.

   • Introduced grooves on the back of handles for enhanced grip and reduced slippage during operation.

     • First prototype did not include this; upon observation of drivers' interactions with prototype and comments, it was later implemented.

3. Improved Button Placement & Security

   • Designed precise cutouts for button integration to prevent loose components and ensure stability during competition.

   • Developed a dedicated wire casing to secure all internal wiring, enhancing safety and durability.

     • After making the second prototype, it was observed that sizing may need to be increased to better encase all wires.

4. Weight Reduction & Structural Integrity

   • Removed excess material in non-load-bearing areas, reducing overall weight.

   • Implemented a Longhorn plus geometric cutout design at the bottom, contributing to both visual appeal and weight efficiency.

Version 1 Model:

Open

Material Selection:

• Frame/Base Plate: Aluminum for its strength-to-weight ratio and durability.

• Handles:

  • PLA/PETG 3D-printed: cost-effective, quick, and customizable

  • Forged Carbon Fiber (TBD): lightweight and high-strength option for performance applications.

Expected Outcomes:

• Enhanced driver comfort and control with improved handle ergonomics.

• Increased visibility and awareness due to optimized frame shape.

• Greater safety and reliability with secured buttons and organized wiring.

• Reduced weight for better steering efficiency without compromising durability.

This redesigned steering wheel aims to provide a high-performance, driver-focused experience tailored for competitive and motorsport applications.