Development of a Prototype Steering Wheel for Simulator-Based Usability Assessment

Steering wheel designs in motorsport have evolved significantly in the last 20 years. Their complexity in particular has increased markedly in terms of secondary controls due mainly to the requirement for the optimization of performance-based settings. There have been multiple occurrences of driver mistakes that have been linked to this increase in complexity, suggesting the need for usability improvements. In order to assess designs, it is necessary to construct prototype wheels for experimental use in a motorsport simulator. This paper describes the processes and equipment required to construct a steering wheel. It covers the development of 3D models, the manufacturing of the chassis, and printing of the 3D structure. The integration and functionality of the electronic components is discussed, in addition to the simulator software configuration. This development structure allows multiple designs to be constructed for relatively low cost and over a short time frame.