3d Printed Racing Wheel

I have always loved racing games, but I found traditional controllers to be uninspiring and unengaging. In the midst of COVID in 2020, I set out to build my own gaming racing steering wheel using only 3D-printed parts and the internals of a $20 Logitech gaming controller. My goal was to create a fully functional, rigid, and immersive racing experience, all without needing expensive, pre-built racing peripherals.

Since real racing wheels have a spring-loaded return to center, I designed a spring mechanism that would allow the wheel to snap back to a neutral position after turning. The joystick potentiometer was mounted at the end of the unit, connected through a gear system that adjusted the steering angle to match the expected joystick input. This solution initially worked but exposed limitations in using delicate, low-cost potentiometers.

One of my key design goals was to ensure the wheel felt rigid and smooth to operate, despite being entirely 3D-printed. I used in-place printed bearing assemblies, which allowed for low-friction rotation with no post-assembly required. I also experimented with a locked ball-bearing concept, where the balls remained stationary to minimize surface area contact. However, in the end, the pre-designed in-place printed bearings provided the best balance of smooth motion and reliability

One challenge was routing the wires from the controller’s circuit board through the rotating wheel. I designed a hollow central axle, allowing the wires to pass through safely without twisting or snagging. A notched opening at the base of the axle ensured that the USB cable and potentiometer wires could exit freely, regardless of the wheel’s angle.

A key aspect of the design was relocating all buttons and triggers from the original Logitech controller to the wheel in a way that felt natural to use. This required precise mounting of components while ensuring the circuit board remained intact. The final result maintained full button functionality while offering a more immersive racing experience.

From a mechanical perspective, the project was a success—the wheel was rigid, smooth to operate, and fully functional. If I were to revisit this project, I would replace the cheap joystick potentiometers with higher-quality, durable potentiometers that could still be recognized by the Logitech controller. This change would significantly improve steering accuracy and longevity. While I ultimately decided that purchasing an inexpensive racing wheel was the most practical option, this project remained a fascinating exploration of custom gaming hardware and 3D-printed engineering.