Manufacturing
Written by: Trevor Bendik
The design process heavily considered manufacturing, such that custom components could be made using 3-axis CNC milling in as few setups as possible. The brake pedal design consisted of 3 custom aluminum components, the Pedal, Mount, and Rail [Fig. 1-2]. This page will be split into three major sections by component.
Fig. 1. 2025-2026 Brake pedal design and exploded view with labeled components
Fig. 2. 2025-2026 Brake pedal custom aluminum components
Pedal
Material: 7075-T651 [Note: T651 is NOT the same as T6, they have different mechanical properties]
Based on geometry, the part took a minimum of three setups using 3-axis CNC milling: OP10 (top side), OP20 (bottom side), and OP30 (pedal pad holes). OP20 (bottom side) required custom 'soft-jaws' due to not having 2 parallel flat surfaces for adequate workpiece clamping and positioning.
