STEM Racing – 1.1 The start – Dyson-Mills Computer Science

The section below covers how we will start to build the car. You will then be able to improve your design through testing.

Whilst the car is obviously a key part of this event the driver, the marketing and all the other sections needed to make a successful team are needed if your team is to be successful.

Drivers can start by practicing their reaction time here.

https://ndovu.org.uk/racing

Learning Fusion 360 for STEM Racing Cars

Here is a guide to help beginners learn the basics of Autodesk Fusion 360 to design a STEM Racing (F1 in Schools) car.

Designing a STEM Racing car requires understanding the basic rules of the competition (like the exclusion zones and minimum thicknesses) and knowing how to use CAD software to model a fast, aerodynamic shape. Before you begin, make sure to review the official STEM Racing rules and resources.

Step 1: Getting Access and Setup

Autodesk provides free educational licenses for students and educators.

Go to the Autodesk Education Community website and create an account.
Verify your student or educator status to unlock the software.
Download and install Autodesk Fusion 360 (often referred to simply as Fusion).
Get a mouse: Fusion 360 is extremely difficult to navigate with a trackpad. A standard three-button mouse with a scroll wheel is essential for panning and orbiting your view.

Step 2: Learn the Fusion 360 Interface

Before trying to design a car, you need to understand how the software works.

The Data Panel (Top Left): This is where your projects and files are saved in the cloud.
The Toolbar (Top): Contains the tools for sketching, extruding, modifying, and assembling parts.
The Browser (Left side): This is your feature tree. It lists every body, sketch, and component in your design. It’s crucial for keeping your work organized.
The Timeline (Bottom): Fusion 360 is “parametric,” meaning it records every step you take. You can go back in time to edit a sketch or feature, and the rest of the model will update automatically.
The ViewCube (Top Right): Click the faces, edges, or corners of this cube to rotate your view.

Step 3: Master the Core CAD Tools

STEM Racing cars are mostly designed using a few core techniques:

2D Sketching: Everything starts flat. You will need to learn how to draw lines, arcs, and splines, and how to apply “Constraints” (like making a line perfectly horizontal) and “Dimensions” (setting a line to exactly 50mm).
Extrude: This pulls a flat 2D sketch into a 3D object.
Loft: This is a more advanced tool that connects two differently shaped sketches (like a square and a circle) into a smooth 3D shape. This is heavily used for the aerodynamic curves of an F1 car body.
Fillet/Chamfer: Tools used to round off or angle sharp edges to improve aerodynamics and safety.
Mirror: You generally only need to design half of the car. You can then use the mirror tool to flip it perfectly across the center plane to create a symmetrical vehicle.

Step 4: Video Tutorials for STEM Racing Cars

The most effective way to learn is to follow along with dedicated tutorials. Mr. Marotti has an excellent, highly recommended multi-part YouTube series specifically designed to walk beginners through creating an F1 in Schools / STEM Racing car from scratch. Another great resource is Peacock Learning Studio.

Follow along with these straightforward instructions to help first-time students create a working basic car:

1. Car Body (Mr. Marotti – Part 1)

How to start your file:

Fusion 360 uses a top-down approach, meaning you don’t need to choose between a “Part” or “Assembly” template before you begin. Every new file is just a generic “Design”. To start along with this first video:

Open Fusion 360: The software automatically opens a blank, new file.
Start a Sketch: Click Create Sketch in the top left toolbar.
Select your Plane: Click on the vertical plane facing you (between the blue and red lines).
Start Drawing: Select the Rectangle tool, click the center origin point, and draw your first rectangle (32.5mm by 50mm) to represent half of the foam block.

This video covers the initial setup and modeling the main fuselage.

2. Canister Housing Fix (Mr. Marotti – Part 2)

Explains how to fix the canister housing.

3. Nose Cone (Mr. Marotti – Part 3)

Explains how to design the aerodynamic nose cone for the front of the car.

4. Axle Holes (Mr. Marotti – Part 4)

Shows how to properly position and cut the axle holes to ensure enough clearance for the wheels.

5. Front/Rear Wings (Mr. Marotti – Part 5)

Explains how to attach aerodynamic features.

6. Standard Car Completion (Mr. Marotti – Part 6)

Wraps up the standard car design.

7. Assembly (Mr. Marotti – Part 7)

Demonstrates how to assemble the wheels and grommets onto the car body to test for clearances.

8. Halo (Mr. Marotti – Part 8)

Covers creating the cavity and inserting the Halo and Helmet components required for competition.

TinkerCAD alternative

Try this if you want to make the car on TinkerCAD.

🔗 Click here to view Mr. Marotti’s full TinkerCAD STEM Racing Playlist

Alternative: Simple Tutorial by Peacock Learning Studio

This offers a slightly different, straightforward approach for beginners in a single video.

Step 5: Manufacture Preparation (CAM Setup)

Once the 3D model is finished, you aren’t done. The car must be physically manufactured, usually out of a standardized block of polyurethane foam or similar material.

Fusion 360 has built-in CAM (Computer-Aided Manufacturing) tools. You will use the CAM workspace to generate the “toolpaths” — the instructions that tell a CNC router machine exactly how to cut your car out of the block of material.

CAM Part 1: Front Block + STL (Mr. Marotti)

Prepares the Fusion 360 model for Machining by creating the front block fixture and exporting an STL file.

CAM Part 2: FNC File Generation in QuickCAM Pro

Walks through setting up the toolpaths and boundaries in QuickCAM Pro to cut the car.

CAM Part 3: 4th Axis FNC Files

Modifies the resulting G-code for 4th axis machining to allow the CNC machine to rotate and cut both sides of the block automatically.

Step 6: Machining with the Holzmann CNC Router

When you are ready to physically manufacture your car, you will use the laboratory’s Holzmann CNC machine. This machine features an offline controller, allowing it to read and execute files directly from a USB drive without needing a dedicated, tethered computer.

Post-Process and Export: Once your CAM toolpaths are fully set up in Fusion 360 or QuickCAM Pro, generate your final instructions by clicking Post Process. Select a standard GRBL or generic G-code post-processor, which converts the toolpaths into a format the Holzmann machine understands (typically exported as a .nc or .gcode file).
Transfer the File: Save your exported G-code file directly onto a USB flash drive. Plug this USB drive directly into the designated port on top of the Holzmann machine’s control box, located next to the red emergency stop button.
Operate the Machine: Power on the CNC router and use the digital display panel mounted on the front-left side of the machine base to navigate the controls. Using this touchscreen interface, open your USB drive, select your exported file, manually jog the router bit to set your XYZ zero point (datum) on your physical material block, and start the machining process.