Ethan Wood-Thomas | Mechanical Engineering

The front gearbox transfers torque from the four-wheel drive chain to the front driveshafts. Removed bulky components and repackaged the system. Simulated a non-linear contact analysis to determine tooth failure, allowing for further weight saving. Moved part of the reduction into the chain to minimize total system weight. Reduced the internal gearbox weight from 6.4 lb to 3.1 lb resulting in a 52% weight reduction. The system performed without failure or complications in 3 competitions.