case Study_Kinematic synthesis: Packaging a Dual-Motor AWD Micro Chassis with 51deg. Davis Steering & 3.5mm Scrub Radius

Overview:

This project focuses on solving the high-density mechanical and electronic packaging bottlenecks of a custom micro-AWD chassis operating within tight spatial constraints.

Key Technical Specs & Design Highlights:

• Steering Kinematics: Custom 51 deg angle Davis steering sweep paired with a tightly controlled 3.5 mm scrub radius to minimize lateral scrub, reduce servo strain, and optimize dynamic steering feel during high-angle actuation.
• Actuation & Powertrain: Twin FA130 drive motors paired with an MG90S micro steering servo operating in tandem.
• Manufacturing & Tolerances: 46-part clamshell gearbox assembly modeled in Fusion 360, specifically calibrated for SLA high-toughness engineering resin tolerances.
• Embedded Control & Electronics: Replaced bulky off-the-shelf ESC modules with a custom panelized PCB layout using ESP-NOW for low-latency wireless control and telemetry.