These carbon fiber components were designed and fabricated for use on a 2-person human-powered vehicle which will compete in NASA’s Human Rover Exploration Challenge in April 2018. These projects were completed with assistance from Lily Douglas, Jason Chang, and faculty adviser Michael Lye.​​​​​​​
Final wheel design:
Our team's goal was to improve upon previous designs to achieve a lighter, stiffer wheel that minimized issues with impact steering and rolling resistance present in previous designs.
Starting with half-scale prototypes, we developed a form to minimize weight and maximize lateral stiffness (A notorious weakness of bicycle wheels) while being conscious of budget and time constraints. The design path was chosen from a variety of concept models considered by the team. The final design was reached through iterative prototyping.

Each 28" wheel weighs in at about 3500g (7lb), and supports over 100kg (220lb) directly lateral to the axis of rotation, and far more axially.
Polystyrene/duct tape concept model at half scale:
First carbon model, fabricated with male molds in two halves, then seamed around the rim:
Second carbon prototype, fabricated with female molds for a dimensional outer surface. Tread concept also applied:
System designed and implemented to quickly interface with and test deflection of the prototypes:
Final mold pattern and fiberglass mold:
Layup guide to communicate process and keep track of progress with various team members who helped fabricate the wheel in shifts:
Trim to true:
Seaming the rim:
Final seat design:
The design of the seat posed a unique set of challenges. While trying to maintain minimum weight, the seat encounters immense force from the riders-especially when pedaling up inclines. As with the wheel, through several iterations of (full scale) trial carbon layup schedules, we arrived at an ideal structure that was strong enough where it needed to be, and reduced as much as possible in other areas.

The final product weighs about 1 pound.
The 2018 Rover in progress:
Folded for transport
My composite contributions for this project included design of wheel, tread, seat, fender and leaf spring components and fabrication assistance. 
My metal fabrication contributions included design and fabrication of the center latch, crank "reaction lever" mounts for our internally geared crank sets, front and rear steering arms/handlebars, seat belt mounts, and more.
The chassis was designed by Ryan Smith and Adrian Roop with faculty advisers Jim Pelto and Michael Lye. 
The RISD Rover will compete in Huntsville, Alabama at NASA's Rover challenge in mid-April 2018.

other work