1. Hexagonal Infill Columns
Aditya Pralhad Patil
Lincoln Shaun Sanders
Jessica Wong

2. Introduction
• 3D Printing Landscape: Functional
Products, Engineering Tooling,
Structural Applications and many
more..
• Interesting Materials (ABS &
Concrete Variants) + Portable
Housing Solution
• Critical Structural Element:
Columns
www.kamermaker.com
www.ContourCrafting.org
To Minimize Material Consumption in a 3D Printed ABS Column for Fixed Load
and Fixed Dimensions through Variation of Percent Hexagonal Infill and its
Orientation
Motivation

3. Model Formulation
1.
ABS Column:
Input Parameters
• Percent Hexagonal Infill
• Infill Angle
ABS Material Properties:
• E = 1,810 MPa
• σy = 29 MPa
• v = 0.35
Diameter 40mm
Length 100mm
Perimeter Wall 1mm
Hexagon Wall 1mm

4. Ansys Simulation Trick
• Fluid Pressure vs Rigid Bodies

5. Constraints
• Fixed Base
• Fixed Displacement(x,y)
• Free Displacement (z)
• Pressure = 2.5 MPa

6. Experimental Validation Plan
Specimen Equipment
Equipment
Printrbot simple metal
Data
Acquisition
• Load Cell (Compression):
Type: Peizo-resistive
Load Capacity: 2 kN
Accuracy: 0.03% Capacity
• Strain gauge Extensometer:
Type: Clip on, resistive
Gauge Length: 25mm
Accuracy: 0.5% Gauge length
• Fiber Bragg Grating (FBG) based Multi Core Fiber(MCF)
Optical Sensing and Interrogator System:
Interrogator Type: 4 Channel
Model: JPFBG-1000, Jphotonics Inc.
Wavelength Range: 1525～1565nm
Optical Fiber Probe Specs:
OFC diameter: 125μm
Type: Silica core type
Computer Control Electronic Universal Testing Machine: Model No. UE1405 , Laryee Technology Co., Ltd
Stress & Radial Deformation

7. Cost Estimation
Sl.no Item Description Price per Unit ($) Quantity Total
1 UTM, rent basis 200 1 200
2
3D Printer- rent per
Job basis
25 1 25
3
ABS filament
consumables
4 Jigs and Fixtures
Included in the
UTM rent
- -
5
Data acquisition
unit-PCI control card
100 1 100
6
MFC FBG Sensor
Interrogator-rent
200 1 Set 200
7 Total NA 1 525

8. Analytical Verification
Model Solid Calculated Solid
Boundary Condition Free-Free Free-Free
Maximum Axial
Deformation
4.3e-4 4.3001e-4
Maximum Radial
Deformation
3.01e-5 3.0298e-5

9. Discretization Study
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0 50000 100000 150000 200000
Tetra Hedron Radial def v/s
Nodes
0.00E+00
5.00E+09
1.00E+10
1.50E+10
2.00E+10
2.50E+10
0 50000 100000 150000 200000
Tetra Hedron Stress v/s
Nodes
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0 100000 200000 300000 400000
HexaHedron Radial def v/s
Nodes
0.00E+00
5.00E+09
1.00E+10
1.50E+10
2.00E+10
2.50E+10
3.00E+10
3.50E+10
0 50000 100000 150000 200000 250000 300000 350000 400000
Hexahedron Stress v/s Nodes

10. Sensitivity Analysis
= 1.675e-13
= 6.05e-13

11. Parametric Study
• Response Variable: Maximum Equivalent (von-Mises) Stress

12. Conclusion
Recommended Column:
• 11% Hexagonal Infill
• 0° Infill Angle
Maximum Stress
• 15.76 MPa
Mass
• 27.88 mg