Custom Utility Trailer Design and Fabrication
This is my undergrad senior project for my Engineering Design Technology bachelors of science degree from Western Michigan University.
A group of 4 students were assigned this project and I was given responsibility of the design and development of the frame. This design had to meet design and safety requirements provided by the Michigan Department of Transportation in order to register the trailer and allow its legal usage on public roads.
A parametric conceptual CAD model has been developed for the creation and fabrication of a custom, user-oriented utility trailer. The development was divided into four subcategories in which each of our group members was assigned responsibility for - frame, utility box, custom tarp, and accessories.
User-oriented custom features include:
- 3500 lbs maximum payload capacity
- User specified hooks around the frame
- Storable loading ramps with calculated clearances for lawnmower loading
- Oak wood utility box with stainless steel trim
- Removable tailgate
- Custom long lasting polyurethane paint job
- Custom fabricated tarp with the capacity of covering 5 ft-high cargo
- Custom stainless steel toolbox
- Tongue weight of 10% of trailer's unloaded weight
Complete conceptual CAD design of frame:
A group of 4 students were assigned this project and I was given responsibility of the design and development of the frame. This design had to meet design and safety requirements provided by the Michigan Department of Transportation in order to register the trailer and allow its legal usage on public roads.
A parametric conceptual CAD model has been developed for the creation and fabrication of a custom, user-oriented utility trailer. The development was divided into four subcategories in which each of our group members was assigned responsibility for - frame, utility box, custom tarp, and accessories.
User-oriented custom features include:
- 3500 lbs maximum payload capacity
- User specified hooks around the frame
- Storable loading ramps with calculated clearances for lawnmower loading
- Oak wood utility box with stainless steel trim
- Removable tailgate
- Custom long lasting polyurethane paint job
- Custom fabricated tarp with the capacity of covering 5 ft-high cargo
- Custom stainless steel toolbox
- Tongue weight of 10% of trailer's unloaded weight
Complete conceptual CAD design of frame:
After the completion of the frame's design, I ran a series of finite element analysis (FEA) to validate my design's structural integrity. Running a factory of safety test at the trailer's maximum payload capacity of 3500 lbs resulted in a safety factor of 3.0, which indicated the final frame design will be capable of withstanding three times its maximum payload capacity before showing signs of wear or failure:
Aside to completing the frame's conceptual design, I had to ensure it was compatible with the rest of the trailer's components' designs by working in parallel with my team throughout the entire design process. This resulted in a smooth final assembly that featured the compatibility of the frame's design with the utility box, tarp, accessories, and common utility trailer components such as springs, axle, tongue jack, and hitch coupler:
[ Fabrication images coming soon ]
After the completion of the fabrication process, we were able to enjoy the final outcome of this fully functional heavy duty trailer. Every feature within this trailer has had thought put into and the outcome was of quality, which fully satisfied our customer. The trailer turned out to be a total of 840 lbs with a tongue weight of 60 lbs, which the customer was extremely impressed with considering the enabled capability of moving the trailer around with one hand, regardless of its heavy weight. The stainless steel utility box is capable of storing the trailer's tarp along with plenty of other tools and utilities.