APEX BUGGY "AZULA" STEERING HANDLE

The steering handle for the new buggy Azula was an attempt at innovating the steering handles that Apex used in their buggies. Steering handles in buggies serve three purposes: 1) a position of security and rest for the driver’s hands 2) the method of controlling the buggy’s direction 3) a mounting point for the brake. Apex typically makes steering handles out of sections of PVC pipes with a central axis drilled through them; a bike brake handle is mounted on one end, allowing the driver to reach forward with their fingers on that hand and pull to brake. 

This design is largely reliable, but contains several problems that the team realized across the years. The first is lack of space; the wide breadth of the bike brake handle requires that the nose of the buggy to be even more wide. Another problem was the unreliability of the bike brake handle, which frequently loosened the braking cable and caused brake rubbing while the buggy rolled. The handle was also difficult to install and maintain, requiring numerous screws, washers, and bolts whos tightness could potentially affect performance.

I took on the project of redesigning the handle with the goal of an equally or more ergonomic design. To save material and for convenience, I integrated the PVC pipe section as the handle portion; I designed a central hub that it could be inserted into. I designed an original braking lever that would provide the same amount of brake cable pull distance and mounted the joint to one side of the handle; the lever’s rotation axis would be parallel to the handle, as opposed to perpendicular to it as before. I used a truss-like pattern across the bottom of the brake lever side to provide support and save material. Originally, I designed the brake to be double-sided, so it could be pulled by either hand; however, I learned from our team’s drivers that that would pinch the hand that didn’t reach forward to brake.

The design was printed and implemented, and seemed to work well. Unfortunately, during its second use on the road, it broke and the buggy crashed into the curb. This was attributed to two key reasons: insufficient infill on the 3D print, and dremeling away of material at key stress point to allow for easier install

The particular design was not tried again, but the inspiration to use 3D printed steering handles has remained.