Crafting a Custom 3D‑Printed Steering Wheel for a Go‑Kart: Lighter, Comfortable, and Modifiable

Building on our effort to reimagine the go‑kart with 3D‑printed carbon‑fiber parts, I recently swapped the stock steering wheel for a custom‑designed wheel that’s lighter, more comfortable, and endlessly modifiable.

A go‑kart steering wheel must be strong, stiff, and comfortable. The stock wheel satisfies the first two with stamped sheet steel and a rubber over‑mold, but its comfort falls short.

I designed the wheel from scratch, tailoring the geometry to my hand size and shape, and drew inspiration from Formula 1 steering wheels. The result was an oblong profile that replaced the original circular shape.

My first OnShape prototype was far from perfect; after two hours of iteration I realized I had misjudged my hand geometry. The finger flutes didn’t align, making the wheel cramped and awkward.

The initial print served as a learning tool. I thickened the grips, removed obstructive protrusions, and added a custom MarkForged logo for branding.

For strength, I selectively reinforced specific layers with carbon fiber—especially those experiencing high shear from the steering shaft hub and mounting hardware. For stiffness, I used Eiger’s isotropic fiber fill to create fiber planes that resist twisting. Read our guide on isotropic fill for more details.

With the new wheel installed, it’s time to tackle another component and replace it with nylon and carbon fiber. Stay tuned!

Want to see the Mark Two in action? Request a demo today!