Roll Over, Rover: Students in "Machine Engineering" Test their Designs

Professor Ryan Halter introduces engineering students to the analysis and synthesis of mechanical components and systems in the fall course. "The element that make this uniquely Thayer is the focus on collaborative design, problem definition driving the solution, and experiential project-based learning integrated into a 10-week class."

He covers static loading conditions and failure analysis, motors and power transmission, and design requirements for linkages, drive trains, and steering mechanisms. "This three-for-one class includes engineering analyses, computer-aided design, and machining and fabrication sessions that student teams leverage to design, fabricate, and demonstrate a complex machine created to complete specified tasks," says Halter.

Says a swashbuckling Sebastian Riano '24 Th'25, in pirate gear as part of the five-person student team that designed Valentina the Pirate: "Our motto was 'Fail fast, learn faster.' We prioritized building and testing parts early on to evaluate their performance under realistic conditions. This helped us identify failures quickly and make iterative improvements."

Every rover finished the course this year, scooping up small objects, traversing the gravel field, and running up and down "Rock Ridge."

Here, students explain their approaches to the challenge:

Crabitron

Crabitron earned cheers from spectators—and second place—with its power take-off transmission mechanism. "Using kit parts and a number of custom-built components, this transmission allowed us to power both the wheels and our virtual four-bar cliff climbing and descent mechanism using only the two motors provided," says Louis Latulippe '25.

Valentina the Pirate

Valentina the Pirate stood out for several reasons. "First, we designed and implemented a remote-controlled stilt system that allowed us to climb cliffs," Riano says. "Second, our rover featured a custom-built drivetrain, allowing for four-wheel drive. Third, we designed and 3D-printed custom wheels with high deformability, which gave them good traction. This made it easier to maneuver around the various obstacles on the course."

Sir Lifts-a-Lot

The Sir Lifts-a-Lot team used only one drive motor—rather than the usual two—which also required a traditional steering system. "Our design featured a gripper that was able to rotate around the robot, allowing us to grab items without the need to precisely line up our robot," says Kolbe Shannon '25, "and large, flexible wheels to act as our suspension system to easily traverse the rocky terrain."

Designated Driver

"What made Designated Driver (right) unique was our commitment to simplicity without compromising functionality," says Gabriella Walsh Th'25. "Our winch design stood out because it cleverly utilized a string lasso taped to the arm, which looped around a pole and detached from the arm to pull us straight up the cliff. This innovative mechanism exemplified how simplicity in the overall design enabled creative and effective solutions."

Chris McGnome 

The Chris McGnome team used a fishing rod concept for the cliff climb in its first-place design. "We used chains between the front and back wheels on each side," says Emma Supattapone '23, "which gave our rover a significant advantage going up and down Rock Ridge and in the gravel field."

WALL-E

"We used a modular design strategy we used that allowed every part of our rover to be attached and detached with ease," says Henry Poret '26 of WALL-E. "This allowed us to test many iterations of each component with minimal adjustment, and even scrap a section that proved inefficient."

Lobstar

The Lobstar team designed a unqiue sweeping "claw" to collect objects along the course.