Angel
For the Lower Control Arm, I first took a picture of the actual thing in real life. In order to make life easier, I decided to use a graph paper to show the scale. Then I use "Insert Canvas" feature in Fusion and scale the image so that the control arm in the image is the actual size. Then I used "Line" feature under "Sketch " tab to trace out the shape of the control arm and then extruded it out. I used " Filet" to round out the outer edge on the left side.
Kathryn
There is a protrusion that sticks out to hold the spring. I first chamfered the edges of the rectangle sticking out. Based on Angel's design of the foundation, I negative extruded the original rectangular form sticking out. I calculated how much to take out by subtracting the protrusion at its thickest by the thickness of the main body. Then, I extruded again, this time making a form that would create the "ledge/hook" like shape. Finally I filleted the edges until it looked similar to the original part from the car.
For the holes for the screw, I used calipers to measure how wide each was and how far away from the edges they were. This allowed me to plot its center point based on the "corner" of the front.
I then extruded the two circles all the way through. Upon closer inspection, I noted that the part had curved parts, which I estimated using the spline tool.
These were some other details where the shape was not flush with the bottom plane. I thought they might also be important for how the piece behaves (i.e. being more flexible and able to absorb stress).
Angel & Kathryn
We attached our printed lower control arm onto our RC car. We realized that the inner end was too wide and it was a tight fit into the space that's meant to hold it. The screws on the bottom were therefore also really hard to screw in, and some were tilted
Practice run of our car on flat ground
Testing our car on the obstacle course
Testing our car on a ramp
Kathryn
Since the design was too wide, I cut down both sides
I remembered to put on a version label
Originally, the larger hole was was too big and loose, so I was going to make the 3.0 mm one smaller to match the 2.5 mm one that fit well. But Mr. Budzichowski let us know he bought heat inserts and after seeing how it would be used we decided to implement them. Since the heat inserts have a diameter of 3.5 mm, I ended up increasing the 2.5 mm hole to b 3.0 mm.
Heat set inserts applied using a soldering iron to heat up the plastic
Kathryn