Modular Sensor Roof Rack Design

About the project

I need a roof-rack system engineered specifically to mount an autonomous-vehicle sensor suite—cameras, LiDAR, and radar—in a clean, reliable, and easily serviceable way. The rack must let me place any of these sensors horizontally, vertically, or at fine-tuned adjustable angles so I can dial in each unit’s field of view without disassembling the whole structure. Your task is to take my rough sketches and dimensional constraints and turn them into a complete mechanical design that can go straight to fabrication. I plan to prototype most parts on an FDM printer and later shift load-bearing components to laser-cut aluminum, so the model needs to include both printable geometries and clear callouts for metal brackets or inserts where extra stiffness is required. If you normally work in SolidWorks, Fusion 360, or similar parametric CAD that’s ideal; STEP and STL exports are mandatory. Deliverables: • Fully parametric CAD assembly of the rack and sensor mounts • Separate printable files (STL) for each 3D-printed component • Flat-pattern DXFs or PDFs for any sheet-metal parts • An exploded PDF drawing with BOM, fastener specs, and torque notes • Quick-reference guide showing the adjustment ranges for every sensor slot There will be other sensors to be installed within the housing as well which is required to be completed for this project. I’ll sign off the project once the digital files drop neatly into my slicer and my fabricator confirms fit with the provided drawings.

Skills required