The document discusses 3D printing technology and its applications. It summarizes three projects that used 3D printing: 1) Testing the strength of fiber-reinforced 3D printed parts compared to aluminum. Finite element analysis and physical testing found the printed parts had impressive strength. 2) Designing and printing a small centrifugal pump. The printed pump was able to pump water to a height of 10-23 cm. 3) Designing and printing the frame for a quadcopter drone. The frame was printed in six pieces to allow for reinforcement with carbon fiber and avoid support material. The printed frame was assembled and added to a functioning quadcopter.
3d Printing: History and Current TechniquesDavid Gerhard
Why do we care about 3d printing? What are the economics of 3d printing? How do the different 3d printers work? How do you design something to be 3d printed?
Developing Breakout Models in FEMAP (Includes Tutorial Walk-throughs)Aswin John
The step-by-step walkthroughs of the presentation are included in the Appendix at the end of this presentation.
This presentation includes:
- Definition of Breakout Models
- When to use breakouts
- [Tutorial] Adding a pass-through in a wing rib
- [Tutorial] Adding boss to orthogrid pressure plate
3d Printing: History and Current TechniquesDavid Gerhard
Why do we care about 3d printing? What are the economics of 3d printing? How do the different 3d printers work? How do you design something to be 3d printed?
Developing Breakout Models in FEMAP (Includes Tutorial Walk-throughs)Aswin John
The step-by-step walkthroughs of the presentation are included in the Appendix at the end of this presentation.
This presentation includes:
- Definition of Breakout Models
- When to use breakouts
- [Tutorial] Adding a pass-through in a wing rib
- [Tutorial] Adding boss to orthogrid pressure plate
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