'Dystopia' Roller Coaster Shell

Designed to be the first carriage in the roller coaster 'Dystopia', this CNC machined shell can fit onto an existing coaster chassis and is themed to suit the overall attraction. 3D printing was utilised as a prototyping option to expose design flaws through the use of support material in the printing process, as it relates to the possible cutting angles of 5 axis CNC machining process.

Extended description:

"Continuing on from the previous assessment where you themed a new amusement park attraction, design in detail one feature of the attraction. Specify on materials selection, manufacturing process and show some form of prototyping."

After theming an amusement park attraction for our first assessment, we were asked to complete a feature of the attraction in greater detail. The attraction which I had designed already was called 'Dystopia', and was based around the story of a lost island used for weapons production which is being over-run by half-human cyborgs set on unleashing their fury to the world. The attraction brings the guest into the story through an interactive shooter roller coaster which scores their hit targets as they race and shoot their way through the lost island full of cyborgs. 

The theming of the attraction sought inspiration from the 'Mad Max' series as well as the 'Water World' movies. I decided to design the roller coaster shell for the ride in more detail. The final concept is to be a combination of hand-assembled parts with CNC routed parts that all fit together on a pre-made chassis to create the shell of the first cart of the roller coaster train. The shell consists of 45 separate parts which are connected together by a series of holes and pins throughout the design. 

3D printing was a suitable method for prototyping all of the parts. The parts which are to be CNC routed can be 3D printed to test draft angles through the use of support material. The less support that part needs, the better off it would be for 5 axis CNC cutting. This prototyping work was a success, with almost all of the parts not needing much support. These parts were then glued together and fitted to a cardboard chassis which had been laser cut from a 2D drawing.