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Print Resilience

As the covers are 3D printed, and are modular, a failed print only ruins one segment instead of the entire wheel cover. With each piece being independent, a bad layer, warping, or bed adhesion failure stays isolated. Keeping material waste and reprint time low when producing a full set.

Curb Rash Guard

Serviceability

Damaged or curb-rashed segments can be removed and replaced individually without tools or taking the rest of the cover apart. The user only needs to replaces what is actually broken. Turning what would normally be a full product failure, into a simple part swap.

serviceability
serviceability

Serviceability

Damaged or curb-rashed segments can be removed and replaced individually without tools or taking the rest of the cover apart. The user only needs to replaces what is actually broken. Turning what would normally be a full product failure, into a simple part swap.

Interlocking Retention

Each segment locks to its neighbors and to the center hub. The geometry maintains engagement under centrifugal force, road vibration, and thermal expansion and contraction. The assembly stays secure even when individual segments are missing or damaged.

Curb Rash Guard

Mix-and-Match Finishes

Due to the segmented design, parts can be printed in different colors or materials and still lock together on the same wheel. This allows intentional color blocking or gradual replacement of worn pieces without forcing a uniform look across the full set.

Curb Rash Guard
Curb Rash Guard

Mix-and-Match Finishes

Due to the segmented design, parts can be printed in different colors or materials and still lock together on the same wheel. This allows intentional color blocking or gradual replacement of worn pieces without forcing a uniform look across the full set.

Individual Upgrades

If a specific part fails or needs improvement, only that segment has to be replaced. For example, when the middle hexagon walls proved too thin and broke during reinstall, the thicker-walled revision could be swapped in without reprinting or discarding the rest of the cover.

Curb Rash Guard

Expanding Hub Engagement

The center assembly passes through the cover and into the original wheel hub. Small nubs expand outward when the center section is pulled, creating a positive mechanical lock against the OEM geometry. This gives the clamping nut a rigid base instead of relying only on friction or surface contact.

Curb Rash Guard

Multi-role Center Nut

The nut both clamps the full cover stack to the wheel and uses a non-standard drive geometry. It sits flush with the surrounding surface, leaving no room for fingers. Removal requires a matching 3D-printable tool, raising the effort needed for casual tampering while remaining fully serviceable by the owner.

Curb Rash Guard
Curb Rash Guard

Multi-role Center Nut

The nut both clamps the full cover stack to the wheel and uses a non-standard drive geometry. It sits flush with the surrounding surface, leaving no room for fingers. Removal requires a matching 3D-printable tool, raising the effort needed for casual tampering while remaining fully serviceable by the owner.

Thread Integrity Under Load

Early versions of the bolt used insufficient wall thickness around the threads. Repeated install and removal cycles caused the layer lines to break and separate, creating a risk of the bolt failing while the car was moving. The solution, increasing the radial wall thickness around the threaded section eliminated the failure mode. The revised geometry has held through continued high-mileage use with no further issues.

Curb Rash Guard

PETG-CF

Used for the large outer segments. PETG-CF prints more reliably at this size than ABS, with lower warping and better bed adhesion on big parts. It also provides the necessary heat resistance for both ambient temperature swings and proximity to the brakes while remaining tough enough for impact.

Curb Rash Guard

ABS

Used for the center hex, locking components, and clips. ABS was chosen where higher strength and better long-term heat resistance mattered more than print ease. These smaller parts can be printed more controlled, so the warping risk of ABS was acceptable in exchange for the mechanical properties.

Curb Rash Guard
Curb Rash Guard

ABS

Used for the center hex, locking components, and clips. ABS was chosen where higher strength and better long-term heat resistance mattered more than print ease. These smaller parts can be printed more controlled, so the warping risk of ABS was acceptable in exchange for the mechanical properties.

Real World Validation

The combination has held up through more than 10,000 miles of mixed weather, including snow, rain, and high heat.

Curb Rash Guard

Sleeping Pods

One hundred pods. One person each. A three-shift, 34-pod version was on the table and got dropped as on a Mars-length trip people need a place that is theirs, and a pod they can make theirs.

The deck stays dark so when you’re in the room you wind down. Each bunk has its own under-cabinet light. A blackout curtain seals the cell.

The mattress converts to a launch/landing seat. It is a worked-out idea, not a flight-qualified mechanism, the goal was to not have to carry 100 beds and 100 seats. Dual-wall structure on the level holds water between the skins: drinking supply and a radiation shelter in the same volume.

Sleeping pods interior, left view Sleeping pods interior, right view
Sleeping pods wide view

Kitchen

A central island is the cooktop and the table. Twenty-five seats attached to the counters can swivel in 0g and 1g, so the room faces itself instead of a wall.

Cooking is magnetic induction. Pans locate on the rings and the heat stays in the cookware. A sink and fill stations handle water and dishes. Dry stores sit in the back side of the ship, with more in storage and utilities. One hundred people eat in shifts. This deck is sized for that, on purpose.

Gym Gym
Gym wide view
Gym Gym

Gym & Wash

Bikes, treadmills, and digital resistance are here so bone and muscle survive the coast. Cardio is belt-loaded for micro-g. That hardware unfortunately is not in the render or the model.

Five full bathrooms, shower and toilet, share the deck. The count is for 100 people on shifts, and for a ship that may later run 1g. The stalls work as normal showers in gravity and as a wash volume in 0g.

Gym and wet rooms share the deck because the stack is tight, the deck is central, and you walk off a workout into a shower.

Kitchen Kitchen
Kitchen wide view

Common Space

Work, recovery, and control share the diameter because the ship does not give you three extra decks.

Command is a dedicated area to check systems through launch, cruise, landing. The lab has a subzero freezer, microscopes, and a sealed volume for opening or testing material that you do not want in the cabin air. Medbay is two hospital beds built for clinic or trauma, whichever shows up.

Five industry leading 3D-printers cover flight parts and crew projects. Bean bags strap down, and are there for 1g and for a break. The large window adds to the open plan and a place to look out.

Common space Common space
Common space wide view
Common space Common space