Faster Lap times thanks to 3D Printing

Faster Lap times thanks to 3D Printing

The technological advancement of 3D Printing has made it possible for PE Racing to master the physics of race pedal design.

The PE Racing Pedal Box is the final product of many 3D printed prototypes.

The PE Racing Pedal assemblies are one of the lightest in the aftermarket.

Founder of PE Racing, Daryl Perusic has engineered & improved performance on the track by delivering savings in weight and more control over driving in equal measure.

From visualization to CAD drawings & models, we were able to test the idea through rapid prototyping with 3D printing. The design may look perfect on the screen, however, it may not be fully functional. Having the 3D printed prototype allowed us to iterate, improve and perfect the ultimate Racing Pedal Box. Once the Pedal Box fully evolved, the design was finalized and fabrication began. Not only did the 3D Printer create faster lap times but it made the design process faster. It eliminated financial, quality & time risks during the prototyping phase.

Each prototype was analyzed and tested, triggering creative ideas for effective solutions to improve the overall performance and reliability of the engineered design. Welding was a major part of the process in the first design of the Pedal Box.

We analyzed the costs involved and decided to redesign the Pedal Box to eliminate Welding, as the process took too long and was not cost effective in the long run. We were successful in the elimination of welding. This resulted in reducing the assemble process of the Pedal Box from 20 down to 4! We consider that a win-win.  

For instance, take a look at the evolution of the mounting feet of the Pedal Assembly.

PE Racing Mounting Feet Prototype for Pedal Racing Box

Above:  Prototype 1, Prototype 2, Prototype 3 (mounting foot)

On the left we have our first prototype, one that consists of welding. The next prototype has a similar mounting foot, but the parts have been bolted together. This was an improvement, but still didn't solve our issue. So, another iteration, we moved forward and designed a billet piece. 

The third prototype is the final product. There is no welding and no bolts. We designed and cut extrusions.  

Thanks to the technological advances of 3D printing, we were able to find the balance between cost, labor and strength faster. 

If you have any engineering problems or products you would like to bring to the market, don't hesitate to get in touch with our team today.

3D printing PE Racing Pedal Assembly

Above: 3D Printed Prototype for the Billet 3 Pedal Assembly