Design, prototype verification, finite-element assessment, and direct-cost evaluation of a wheelchair-accessible low-speed electric campus buggy for inclusive mobility

Zammeri Abd Rahman; Saiful Bahri Mohamed; Rodianah Alias; Mohd Sobri Hamid; Mohd Shahir Kasim; W. Noor Fatihah W. Mohamad; Wan Ahmad Luqman Ellias Wan Saidi; Ahmad Syauqi Azlan

doi:10.15282/ijame.23.3.2026.2.1038

Authors

Abd Rahman, Z. Design Optimization and Manufacturing Research Group, Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia , Sultan Zainal Abidin University https://orcid.org/0000-0001-5582-8823
Mohamed, S. B. Design Optimization and Manufacturing Research Group, Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia , Sultan Zainal Abidin University
A. Rodianah Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia , Sultan Zainal Abidin University
Hamid, M. S. Design Optimization and Manufacturing Research Group, Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia , Sultan Zainal Abidin University
Kasim, M. S. Design Optimization and Manufacturing Research Group, Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia
W Mohamad, W. N. F. Design Optimization and Manufacturing Research Group, Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia , Sultan Zainal Abidin University
Wan Saidi, W. A. L. E Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia , Sultan Zainal Abidin University
Azlan, A. S. Faculty of Innovative Design and Technology, Universiti Sultan Zainal Abidin, Kampus Gong Badak, 21300 Kuala Nerus, Terengganu, Malaysia , Sultan Zainal Abidin University

DOI:

https://doi.org/10.15282/ijame.23.3.2026.2.1038

Keywords:

Inclusive Campus Mobility, Low-Speed Electric Vehicle , Wheelchair Accessibility , Prototype Verification , Energy–Cost Assessment

Abstract

Mobility between campus buildings can remain inaccessible even when individual facilities are barrier-free. This study developed and verified a wheelchair-accessible, low-speed electric campus buggy in which boarding access and manufacturability in workshops were considered from the concept stage. A requirements-driven Design Thinking process was combined with design-for-manufacture principles, CAD modelling, linear static finite-element analysis, full-scale prototype fabrication, controlled engineering tests and direct-cost assessment. The prototype uses a welded AISI 1020 tubular ladder frame, a continuous low anti-slip floor, open side access, multi-row seating, side guards, a canopy and a detachable boarding ramp. Under the final static vertical load case, the chassis model produced a maximum von Mises stress of 140.0 MPa, a maximum equivalent strain of 4.521 × 10⁻⁴, a maximum resultant displacement of 2.724 mm, and a minimum factor of safety of 2.511. The ramp remained elastic up to 180 kg, the mean stopping distance increased from 3.9 to 5.4 m at 15 km/h as the payload increased, and wheel lightening occurred at 24° for the driver-only condition and 21° under load. Estimated energy consumption was 184–238 Wh/km, while the corrected direct prototype cost was MYR 36,363.16. The findings support continued controlled prototype development rather than service certification, with higher ramp proof loading, positive wheelchair securement, instrumented braking, direct centre-of-gravity measurement, and durability testing identified as priorities before routine deployment.

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