Brake pedal

· Client  : YUSAE (Yeungnam University Society of Automotive Engineers)

· Role     : 

Supported the production of a brake pedal prototype 

with DfAM design for the competition.

Harvestance was exploring 3D printing cases for mobility

 with YUSAE and decided to try to make a brake pedal. 

[First Brake Pedal Model Shape] 

Material : Steel, weight: 330g 

Previously, the brake pedal was manufactured 

by laser cutting the steel plate and welding 7 parts. 

1. Changing Material and Manufacturing Method

Produced high-intensity, high-performance brake pedal

by utilizing the freedom of shape, which is the advantage of 3D printing and composite materials.

→ Carbon Fiber Composite material 
Laser cutting & Welding → 3D Printing

Used Onyx as the base material and 

optionally reinforced carbon fiber where additional stiffness is required.

Onyx is a material consisting of plastic nylon and carbon monofiber,

If you reinforce carbon long-fiber, 

It will have a stiffness equivalent to Al6061

2. Geometric optimization

When using 3D printing, 

along with changing materials and processing methods, 

the most important element of the design optimization process has increased the efficiency of the parts.

· To create optimal design, Harvestance utilized Generative Design, which has recently become 

   a hot topic in the design industry.

Generative design is an AI-based automated design creation tool.

   It is useful for creating structurally optimized, consolidated designs based on processing methods,            materials, boundary conditions.

Initial Model

Generative Design

Final Model

3. Selecting 3D Printing Conditions

The optimal printing direction is determined by considering the location of the geometry that requires stiffness,

 and the area where the support will be generated is also considered.  

For 3D printing of composite materials,

The printing process is also an important part.

The direction of printing changes the area where the carbon fiber can be reinforced.

4. 3D Printing

Markforged's 3D printer used in this application can easily remove support structures by hand, 

and has fewer scratches on the surface, making post-processing very convenient.

3DPrinting Application





7개의 부품

소재 변경 + 3D프린팅

Onyx + 탄소 섬유 


7개의 부품 

소재 변경 + 3D 프린팅 + 디자인 최적화 

Onyx + 탄소 섬유 


1개의 부품


Original Model

Changing material + 3D Printing

Changing material + 3D Printing 

+ Optimized design


Onyx + Carbon Fiber 

Onyx + Carbon Fiber 




7 Parts

7 Parts

1 Part