College - Author 1

College of Engineering

Department - Author 1

Mechanical Engineering Department

Degree Name - Author 1

BS in Mechanical Engineering

College - Author 2

College of Engineering

Department - Author 2

Mechanical Engineering Department

Degree - Author 2

BS in Mechanical Engineering

College - Author 3

College of Engineering

Department - Author 3

Mechanical Engineering Department

Degree - Author 3

BS in Mechanical Engineering

College - Author 4

College of Engineering

Department - Author 4

Mechanical Engineering Department

Degree - Author 4

BS in Mechanical Engineering

Date

6-2026

Primary Advisor

Lauren Rueda, College of Engineering, Mechanical Engineering Department

Additional Advisors

Rich Murray, College of Engineering, Computer Engineering Department

Abstract/Summary

Cal Poly’s Poly1Rover team, advised by Professor Rich Murray, aims to deploy four student-designed mini-Mars rovers, each equipped with a sample-tube retrieval claw, before 2030. However, the wheels of Poly1Rover’s current 6th generation rover are not ready for deployment to Mars, as they do not utilize space-grade materials, are not optimized for manufacturability, and lack sufficient spoke compliance to absorb landing and high-impact loads. This project will be developed by a team of Mechanical Engineering students at California Polytechnic State University, San Luis Obispo (Cal Poly): Daniel Hudak, Dylan Mack, Presley Sacavitch, and Ryan Trevena. Next Intent is providing funding and manufacturing for the wheel and hub of the 7th generation Poly1Rover in collaboration with Professor Murray.

The chosen wheel design is optimized for durability, traction, and manufacturability while remaining compatible with the rover and within the wheel assembly’s target weight. The wheel is to be manufactured from aluminum alloy 7075, a high-strength, space-grade material, ensuring durability across rough, uneven terrain and extreme temperature changes on Mars. The wheel includes raised treads for improved traction on Mars terrain. The overall geometry was optimized for manufacturability by maintaining sufficient clearances for tool access. Simplified spokes were also used to improve machinability for fabrication on a 3-axis CNC mill. The aluminum wheel is fastened to a central titanium hub using six titanium M3 screws. The hub mounts onto the motor shaft with a slip fit and is retained by an M3 set screw. The hub and shaft also include aligned through-holes for a hairpin cotter pin to provide a fail-safe mechanism if the set screw loosens during operation.

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