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Presentation on

Innovative Product Design with FDM

By�

Asif Rahman

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Table of Content

• CHARLES HULL, BY WHOM 3D PRINTING WAS FIRST COMMERCIALIZED IN 1980�
• WITH THE SUCCESSIVE ADDITION OF THE MATERIAL LAYER UPON LAYER FROM COMPUTER-AIDED DESIGN (CAD) DRAWING, A PHYSICAL OBJECT CAN BE CREATED BY THE 3D PRINTING PROCESS �
• 3D PRINTING IS USED TO CREATE DIFFERENT MECHANICAL PARTS, PROTOTYPES, FUNCTIONAL EQUIPMENT, BIO-TISSUES, AND EVEN A FULL STEEL BRIDGE IN AMSTERDAM [2]

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Introduction

Additive Manufacturing Process

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Additive Manufacturing Types

FUSED DEPOSITION MODELING (FDM)

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• FDM is an additive manufacturing process where a thermoplastic filament is pushed through an extruder and deposited in a certain predetermined path layer by layer to get the desired object

Schematic view of FDM process

PRODUCT TYPES

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Product 1: Bionic Bracket

Product 2: Bridge

INSPIRATION OF THE DESIGN: BIONIC BRACKET

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Product 1

Designed inspired by the butterfly

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3D Model Development

Part 1 : Bionic Bracket

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Specifications

• Dimension: 80 X 40 X 40 mm

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• Circle diameter: 18 mm

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• Base Thickness: 3 mm

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• Weight: 7 gm

Material: CFRP

Material: ABS

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File Repairing

Software: Autodesk Netfabb

Part 1 : Bionic Aircraft Cabin Bracket

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Before Repairing : 6572 Triangles

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After Repairing : 6676 Triangles

INSPIRATION OF THE DESIGN: BRIDGE

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PRODUCT 2

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• Exploring the research works

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• Maximize the load bearing to weight ratio

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• Material consumption

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• Integrating honeycomb design in arc bridge

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Turris Lybisonis Bridge [1]

Designed Prototype Bridge

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3D Model Development

Part 2 : Load Bearing Bridge

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Specifications

• Dimension: 80 X 40 X 20 mm
• Cross sectional Area: 1492.28 mm²
• Wall and Arch Thickness: 3.3 mm and 2.74 mm respectively
• Weight: 31 gm
• Material : ABS

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File Repairing

Software: Autodesk Netfabb

Part 2 : Load Bearing Bridge

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Before Repairing :940 Triangles

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After Repairing : 996 Triangles

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Simulation Results

on Fusion 360

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DIRECTION OF APPLIED FORCE

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Outcome from simulation force

End-product after the lab test

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Applied Force with Time

Applied Force with stroke

Lab Experimental Results

• A novel Bio inspired "Butterfly" aircraft has been designed for an aircraft cabin bracket.

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• A unique Arc based honeycomb prototype bridge has been designed.
• Before printing, both the part's STL files are repaired in the Autodesk Netfabb to ensure the accuracy of the designed parts

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• The simulated load testing results show that the prototype bridge has ultimate tensile strength is 29.6 Mpa.

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• On the physical lab environment test, the maximum withstand load is 1704N for the prototype bridge.

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• The load bearing to mass ratio for the prototype bridge is 54.96 N/gm with a total duration time of the applied force is 66.06 seconds.

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•  On the lab test, the part is displaced approximately 1.65 millimeters before the load has been removed.

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Summary

CONCLUSION

• 3D printing is a great tool for designing and testing prototypes and functional parts.

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• The maximum withstands force in the lab is found 1704N, which is way less than the simulated load testing results in Fusion 360.

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• So, there is an opportunity for future work to investigate how the deviation of the physical lab test results differs from the simulation-based environment.

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THANKS FOR YOUR TIME!

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REFERENCE

1. Mura I, Odoni Z, Perra M (2003) Static analysis of the Turris Lybisonis Roman multispan stone arch bridge. In: Brebbia CA (ed) Structural studies, repairs and maintenance of architecture VIII, vol 16. WIT Press, Southampton, UK, pp 667–674Mura I, Odoni Z, Perra M (2003) Static analysis of the Turris Lybisonis Roman multispan stone arch bridge. In: Brebbia CA (ed) Structural studies, repairs and maintenance of architecture VIII, vol 16. WIT Press, Southampton, UK, pp 667–674
2. MX3D to install world’s first 3D printed steel bridge over Amsterdam canal. (n.d.). 3ders.Org. Retrieved March 4, 2023, from https://www.3ders.org/articles/20180403-mx3d-to-install-worlds-first-3d-printed-steel-bridge-over-amsterdam-canal.html

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