Luge is one of the fastest and most precise events in the Winter Olympics. Athletes race down an icy track at incredible speeds, relying on smart design, balance, and control. In this engineering challenge, students take on the role of Winter Olympic engineers—designing a luge sled and protective egg capsule that can safely carry a fragile “athlete” to the finish line.
This project blends creativity, physics, and CAD design as students explore impact forces, friction, stability, and material choice. The goal is simple: get the egg down the luge without breaking—but how students solve that problem is entirely up to them.
Project Overview
Students will design and build:
- A mini luge sled that travels down an icy track
- An egg protection system that prevents cracking during the run
The luge will travel down a sloped surface designed to simulate icy terrain (smooth plastic, laminated board, cardboard with wax paper, etc.).
Your Challenge
Design a luge sled and egg protector that:
- Carries a raw egg safely down the track
- Minimizes impact forces and bouncing
- Remains stable and upright
- Fits within the provided size constraints
Basic Luge Specifications (Classroom-Friendly)
These specs give structure without over-constraining creativity:
Track (Instructor-Provided)
- Length: 3–6 feet
- Angle: 20–30 degrees
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Surface Options:
- Laminated cardboard
- Plastic poster board
- Foam board covered with wax paper or plastic wrap
- Optional: Side rails (1–2 inches tall) to keep sleds on track
Luge Sled Constraints
- Max Length: 8–10 inches
- Max Width: 4–5 inches
- Max Height: 4 inches
- Egg Orientation: Student choice (horizontal or vertical)
- No adhesives on track
Egg Rules
- Raw egg (standard chicken egg)
- Must be visible or easily removable after run
- No pre-hardening or chemical treatments
Allowed Materials (Instructor Adjustable)
- Cardboard, cardstock
- Craft foam, felt, cotton
- Popsicle sticks, wooden skewers
- Rubber bands
- Straws
- Bubble wrap or paper towels
- 3D-printed parts (optional)
Beginner Version
Focus: Protection + Stability
- Design a simple sled platform with runners or a flat base
- Create a cushioned egg holder using soft materials
- CAD tasks:
- Sketch sled base
- Extrude simple walls or rails
- Model egg cavity (basic cylinder or oval)
- Test multiple runs and refine padding placement
Advanced Version
Focus: Optimization + Engineering Tradeoffs
- Design aerodynamic sled shapes
- Model crumple zones or shock-absorbing structures
- Optimize:
- Egg position (center vs. rear)
- Runner spacing and thickness
- Weight distribution
- CAD enhancements:
- Parametric egg holder sizing
- Multi-body sled assemblies
- Cutouts to reduce mass without sacrificing strength
Optional twist:
- Fastest unbroken egg wins 🥇
CAD Fundamentals for the Egg Drop Luge Challenge
Students should focus on these key CAD skills:
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Sketching & Extrusions
- Create sled bases, runners, and egg holders
- Extrude sketches into 3D parts
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Symmetry & Mirroring
- Ensure runners and supports are evenly balanced
- Use mirror tools for precision and efficiency
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Assemblies
- Combine sled base and egg protector
- Check alignment and egg clearance
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Parametric Design
- Use dimensions to adjust egg cavity size
- Quickly refine designs after testing
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Material Thickness & Structure
- Model walls and padding zones with realistic thickness
- Avoid overly thin parts that may fail on impact
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Optional Motion & Impact Thinking (Advanced)
- Predict where forces act during descent and landing
- Design features to redirect or absorb energy
Testing & Iteration
- Each team gets 1–3 test runs
- After each run, students may adjust padding, egg position, or sled geometry
- Encourage documentation of design changes and results
Scoring Ideas (Optional)
- Egg Survived (required!)
- Best Engineering Design
- Smoothest Ride
- Most Creative Egg Protection
- Fastest Safe Luge