Printing large 3D objects with interlocking part design

Zulkifli, Nurul Atiqah (2017) Printing large 3D objects with interlocking part design. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This project is focused on three different interlocking designs of hinges, planar and snap fit in order to determine the optimum interlocking design to print large 3D object. Each design is made to be assembled together to form a hollow cube shaped size of approximately 200mm x 200mm x 200mm. Since the 3D printer are unable to print large object than its working volume, the large objects needs to be partitioned first and then assembled in order to form the large objects. In order to determine the optimum interlocking design, finite element analysis is done to determine whether the design will fail under certain applied pressure. In this project pressure of 1MPa, 2MPa, 3MPa, 4MPa, 5MPa, 6MPa, and 7MPa are applied to the body part of interlocking design. Hence by using Structural Analysis from ANSYS software, the result of the Finite Element Analysis of each interlocking design can be obtained. The results analysed from the Structural Analysis are total deformation, equivalent stress and safety factor. Thus, the result between the three interlocking design of hinges, planar and snap fit are compared to determine the optimum interlocking design to print large object. The material used for this project is the Acrylonitrile Butadiene Styrene (ABS) material. Each of the interlocking design is fabricated by UP-PLUS 2 machine. From the result, it is concluded that the snap fit interlocking design is the optimum design to print large objects. This is because, the snap fit interlocking design can withstand the highest maximum pressure applied of 6MPa to be compared with hinges interlocking design that could only withstand 1MPa of pressure applied and planar interlocking design that could only withstand 3MPa of pressure applied.

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