Engine Project
This project involved the design and fabrication of a functional scale model of an internal combustion engine, completed as part of a sophomore engineering design course. The objective was to create a fully assembled 3D-printed engine capable of rotating smoothly, requiring precise tolerances, accurate geometry, and consideration of piston-crankshaft dynamics. Modeled after a V8 LS engine, the project went beyond simpler two-cylinder designs to introduce greater complexity in crankshaft design, firing order, and motion analysis. Alongside the CAD and prototyping process, hand calculations and SolidWorks Motion simulations were conducted to analyze piston displacement, velocity, and acceleration. Thermodynamic principles were applied to estimate power output, torque, and performance trends. The final deliverable included a working engine model and a professional poster presentation summarizing the design process, iterations, and analysis results.
Modeling
The design phase began with the breakdown of an LS V8 engine into its critical geometric and dimensional features, including piston and cylinder diameters, connecting rod lengths, and crankshaft geometry. These values were incorporated into SolidWorks to create a detailed 3D assembly consisting of engine block halves, crankshaft, pistons, connecting rods, and pins. Careful attention was given to clearances, ensuring that moving components operated without interference while maintaining sufficient tolerance for smooth rotation. SolidWorks’ assembly and motion tools were used to validate the kinematic motion of the crankshaft and piston system before fabrication. Iterative modeling and prototyping refined the design to achieve a balance between manufacturability and mechanical accuracy.
Calculations
The analytical portion of the project paired with coursework in dynamics. Planar motion equations were applied to calculate piston displacements, velocities, and accelerations throughout the engine cycle. These hand-derived results were compared with data from SolidWorks Motion analysis, allowing for direct evaluation of simulation accuracy versus theoretical models. Additional thermodynamic calculations estimated compression ratios, cylinder volumes, and predicted work output. Using simplified cycle assumptions, engine power and torque curves were generated to illustrate expected performance across engine speeds. This analytical component reinforced the connection between theoretical engineering principles and practical mechanical design.
Final Product
Multiple prototypes were fabricated using additive manufacturing to validate tolerances and refine the assembly process. The final model consisted of super-glued 3D-printed components and successfully rotated under external actuation, demonstrating proper clearances and motion of all eight cylinders. The engine was presented alongside a professional poster that documented the iterative design process, kinematic and thermodynamic analyses, and key engineering decisions. The outcome validated both the accuracy of the CAD assembly and the effectiveness of the applied calculations, while also demonstrating the ability to deliver a complete engineering project from concept through presentation.
Skills Learned
This project reinforced the application of engineering theory in a practical design context. The integration of dynamics calculations, thermodynamic performance estimation, and CAD motion simulations emphasized the importance of validating results through both analytical and computational methods. Key lessons included the role of tolerances and clearances in achieving functional mechanical assemblies, the necessity of considering interference and geometry in moving systems, and the value of iterative prototyping to refine designs. Beyond technical skills, the project highlighted essential professional practices, such as managing deliverables under deadlines, coordinating team responsibilities, and effectively communicating results through technical documentation and presentations. Collectively, these experiences built a foundation of mechanical design, analysis, and project execution skills directly transferable to professional engineering environments.