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Homecoming Float Batmobile Replica
Homecoming Float Batmobile Replica
For my Fall 2025 manufacturing project, I produced a 3:10 scale model of the fictional Batmobile from the 1989 film Batman. The car was to be used as part of the senior class homecoming float (with Batman theme) and had a strict three-week time constraint to finish the project.
The proposed model would be shaped out of 0.5” plywood sheets placed at specific cross sections to create the profile of the car. Then, cardboard strips would be laid down across the cross sections to fill in the gaps and provide a paintable surface for the exterior finish. The proposal was approved by both Ms. Richmond and the senior class president.
The profile of the car was modeled in Fusion 360 using pictures from the film as reference. The profile was divided into nine sections that best represented the unique shape of the car without using too many sections that would increase the time, cost, and weight. The final model (see right) was shrunk down to approximately 30% of its true size to account for machine size limitations and space allocation on the float (6ft).
CAD of all nine cross sections of the Batmobile
The resulting CAM process was relatively simple. Each section (see below) was split in half to allow them to fit within the 2x4’ movement limits of the Tormach 24R, and then machined one at a time using default contour settings for wood routing. The only difficulty encountered during the machining process was workholding the low quality plywood (supplied by class treasurer) in a way that prevented the wood from bowing or bending when laid flat on the bed. I found that machining the side with the edges bowed up (rather than the middle) tended to produce a better result in terms of cutting depth and tab thickness.
Section(s) 2 and 8
Midsection
Finished Senior class float
The remainder of the project was more akin to arts and crafts than engineering. Strips of cardboard were cut down to a rough estimated size and shape, then stapled across the cross sections to produce the topology of the Batmobile. Minor details, such as the turbine, were added using 3D printed parts, then fastened to the main body with construction screws. Finally, the entire car was spray painted and fastened to the float (see right).
Final Product
Final Product
The Senior class won in the float building competition, thanks to the help and efforts from everyone involved. Most agree that the awesome Batman centerpiece of the float helped push it to victory as well!
If more time allowed, I would have spent more time creating the little details like the turbine in the front. There are dozens of exhaust pipes, grapple guns, and more details that I simply did not have time to include. I also should have attempted to make the transitions between cardboard less noticable.
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