When Precision Becomes the Problem

Engineers get Onshape Professional up to 6 Months Free: https://onshape.pro/Edisonmotors This build should have gone smoothly, but a small mistake turned into a major lesson. After scanning an axle, modeling it in CAD, and designing custom suspension brackets, everything fit perfectly on the screen. Once the parts hit the shop floor, tight tolerances, weld distortion, and real-world variability created fitment problems that forced redesigns and rework. At the same time, a supplier error placed brake chambers in the wrong position on one of the axles, creating a potential production delay of months. Rather than waiting, the team sourced a local replacement and adapted the build to stay on schedule. It is a behind-the-scenes look at how real manufacturing problems get solved under pressure. Along the way, you will see a custom starlight headliner build, suspension assembly, and the full CAD-to-production workflow using 3D scanning, Onshape, and 3D printedprototypes. If you enjoy engineering, fabrication, trucking, and real-world problem solving, this episode shows what it actually takes to build trucks from the ground up. Join this channel to get access to perks: https://www.youtube.com/channel/UCUEzfzqf2fx3C1vs0MlgShA/join 0:00 – Introduction 0:26 – We’re getting a starlight headliner 1:18 – Starlight headliner modes 1:51 – Joel 1:55 – 3D scanning the mechanical truck axle 2:31 – Designing custom suspension brackets using Onshape 4:31 – The 3D printed suspension bracket4:59 – Mechanical truck manufacturing update 10:23 – Assembling the mechanical truck 10:52 – Supplier mistake and delays 12:03 – Installing the front axle 13:26 – New axles and tolerance challenges 14:18 – Tolerance masterclass 17:05 – Conclusion