Winning the MUCAT Competition

April 2025

After extensive work on what was a school project, we developed an inflation-based standing assist, an easily detachable battery and motor system, and stuck some cushions onto it and went into the presentation. This prototype was… Bad. It required a good kick every once and a while to keep functioning. We were shocked when we won the $25,000, which served as our seed money then onward.

Design Iterations: Key Lessons from Our Pre-2026 Prototypes
Our early design iterations taught us exactly what not to do. Initially, we iterated toward skeletonized 3D-printed structures. While aesthetically pleasing, these designs suffered from critical durability issues, excessive material flex, and generally high assembly complexity. The performance gains were… marginal at best. The ordeal taught us many valuable lessons, however. It guided us towards entirely new drivetrains, pristine material selections, and Contract Manufacturing partners.

  • Injection molding: Protolabs has phenomenal automated DFM (Design for manufacturing) support – Throw in your file, and you can get consultant-grade feedback on your part’s injection moldability. Starting with Protolab’s tools is key to get your part’s design dialed in, even if you plan to use a different provider.
  • Cost winner: China’s JLC and PCBWay and their subservices have unbeatable cost for… basically everything. Surprisingly, lead times don’t suffer dramatically. 5 days for manufacture and 2-4 business days shipping for 3D prints from JLC. JLC also has its own much cheaper version of the Master-Mccar catalog.
  • Lead time winner:SendCutSend is the other contender for sheet metal – it has a beautiful UX, faster lead times, and is made in America – but could cost you 10x more. I do not recommend it unless you have to crash your project timeline.