3D-Printed Roller Coaster Electrical Lead
Role:
Electrical Lead, Launch Designer
Organization:
Theme Park Engineering and Design
Dates of Involvement:
Fall 2025-Spring 2026
Relevant Skills:
- Electrical Design
- Mechanical Design
- Arduino Programming
- Motor Control
Overall Summary
This project involved creating a roller coaster layout in SolidWorks, modeling theming and support structures, and constructing a fully functional coaster. As the electrical lead, I managed the controls for the station, launch, and control panel while also designing the control panel in CAD. I additionally supported the launch design, including the motor mounts and drive wheels.
Electrical Design
The launch electronics are centered around an Arduino, which controls train dispatch from the station and the speed of the launch motors. Each motor is driven by an independent speed controller, allowing precise adjustment of individual motor speeds. This enables a controlled speed ramp during the launch and more precise control of the station motor.
Aesthetics of Electrical Integration
Maintaining the coaster’s theming while integrating the electronics was a key design priority. To conceal the wiring and electrical components, the coaster baseplate was elevated, creating space beneath the track for routing and housing components. Protective enclosures were designed for delicate electronics, along with dedicated paths for wire routing between the control box, station, and launch motors. Themed elements were also positioned around the motors and station track to further conceal wiring without compromising accessibility.
Control Panel Design
The control panel was designed to give operators intuitive control over the coaster while keeping the interface simple and easy to understand. It features an emergency stop that cuts power to the control system, a dispatch button, a safety toggle for the launch, a battery voltage indicator, and a launch power control knob. The Arduino serves as the central controller, coordinating these inputs to manage coaster operation.
Takeaway
Designing the controls and electronics for this 3D-printed roller coaster was a valuable engineering challenge and learning experience. I gained experience in launch motor mechanical design, electrical system integration, theming preservation, and human-machine interface design. The project allowed me to develop and apply skills outside my previous experience, broadening my engineering knowledge and adaptability.
