2. Additive Manufacturing
• Adds material to build up a structure rather than removing it
as waste.
• Effective for its ease of use, fast prototyping, flexibility, and
lack of waste
• Struggles because of limited materials, slow production
speeds, and relatively low precision
5. As Strong As Aluminum?
• The Mark One has the capability to reinforce its nylon prints
with structural fibers like fiberglass, kevlar, and carbon fiber.
• Claims to make the strength of the printed parts rival that of
aluminum
• My research has been to test the claims.
6. SolidWorks Simulation
•Finite Element Analysis
(FEA) breaks down
solid objects into small
pieces with a “mesh”
Software balances the
relevant conditions for
each vertex of the
elements
7. SolidWorks Simulation
•Learned to use the
static simulation
tools
•Set up a basic load
test for a solid
aluminum square
beam
Stress
Displacement
8. •First modeled the core
of the printed part as
pattern of triangles
• Slow rebuild times, edits
take too long to load
Tried approximating the
triangles as circles to
improve the speed
Reduced edges by 77%
and faces by 66%
Improvement but still fairly
slow
Creating the 3D Printed Model
9. •Model the honeycomb
core of the print as a
new material
•Orthotropic materials
have different
properties in the
different coordinate
directions
•Ex: wood, fiberglass,
carbon fiber. Max
strength along the
length of the fibers
Orthotropic Material
10. • Creating a core with the
new material sandwiched
between layers of fiber:
• The boundary condition
between the layers was
defined as bonded
• The same load condition as
the aluminum beam was
applied to this model
Simulating the Model
13. • Plot Force vs.
Displacement data
Elastic deformation leads
to linear relationship
14. Conclusion
• The fiber reinforced plastic (FRP) has impressive strength
• Aluminum according to the simulation is much stiffer than the
fiberglass FRP
• The FRP however may be able to handle a similar weight
before complete failure.
16. 3D printing
● Decreases time to
prototype
● Mark One
○ Strong/working
parts
○ Can reinforced
nylon with
Fiberglass,
Kevlar, and
Carbon-Fiber
17. Pumps
● Mechanical and Chemical
Engineering meet
● How do we effectively and
efficiently move liquids?
● 2000 BC Egypt and the
shadoof
● 1851 John Appold invented the
centrifugal pump
18. Starting point
● Thingiverse
● Major components
● Problems
○ Small (about the size
of a quarter)
Source: http://www.thingiverse.com/thing:4839
20. Unit Value
Mass Flow Rate Inlet [kg/s] 0.0361
SG Mass Flow Rate
Outlet
[kg/s] -0.0361
Pressure Drop [Pa] 56.9
Simulation Data
● Mass is conserved
○ “Watertight”
● Difference in Pressure
22. Head Height
● How high can the pump push a liquid against gravity
● A simple measure of performance
● Higher the head = more powerful the pump
23. Test Notes
● Trial 1
○ Head height 23 cm
● Trial 2
○ Head height 10 cm
● Trial 3
○ Head height 15 cm
● Problems
○ Troubleshooting
○ Impeller speed
control
○ Motor damage
○ My lack of experience
24. Next Step
● Increase sample size
● More thought on holding tanks
● Use fiberglass
● Find better ways to seal
26. Presentation Outline
• Use SolidWorks and the 3D printer to design and
produce the frame of a quadcopter.
• Build a functioning 250 class quadcopter with the printed
frame.
– Note: 250 is the distance from motor center to motor
center along a diagonal, in millimeters.
27. Crucial Components
• Flight Controller
– Automatically
Stabilizes Flight.
• Motor Controllers
– Adjust speed of
motors.
• Together they are
responsible for
producing all the
possible movements.
29. Initial Goals
• Print the entire frame in one piece for added strength.
• Save weight.
• Reinforce the Nylon with Carbon Fiber.
• Mount a camera for aerial photography.
• Frame should look aggressive and fast.
31. Early learning curve
• Initially was attempting to design and print
in one piece.
• This goal was being hampered by the size
of the print bed.
• Print size is:
– 320mm X 132mm in
the plane of the bed.
– 154mm vertically.
32. Design Process
• Realized the print bed was constraining the size too
much.
• Thought about printing it in two pieces.
33. Design Process
• Decided against printing it in two pieces:
– Would have been very hard to print a fastening
system that would be strong.
– The place of connection would be right by all of the
electronics.
• Decided to print in six pieces:
– Two base plates
– Four arms.
34. Other Printing considerations
• The mark one prints layer on top of layer.
• Thus overhanging structures require support material.
• With numerous things such as ribs in an arm this can
become a huge nuisance.
• Decided to avoid support material by designing with
method of printing in mind.
35. How the Mark One prints Fiber
• Fill types for fiber:
– Isotropic
– Full
– Concentric
36. Troubleshooting my Arm
• The only fill type available for Carbon Fiber is concentric
• The shape of the arm was not working for concentric fill
• This forced me to choose Kevlar instead
• Initially my arm was 5mm thick
• After printing with Kevlar it was too flexible
