Hexagonal Infill Columns

Aditya Pralhad Patil

Lincoln Shaun Sanders

Jessica Wong

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

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

Ansys Simulation Trick

• Fluid Pressure vs Rigid Bodies

Constraints

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

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: 125μmType: Silica core type

Computer Control Electronic Universal Testing Machine: Model No. UE1405 , Laryee Technology Co., Ltd

Stress & Radial Deformation

Cost Estimation

Sl.no Item Description Price per Unit ($) Quantity Total

1 UTM, rent basis 200 1 200

23D Printer- rent per

Job basis25 1 25

3ABS filament

consumables

4 Jigs and FixturesIncluded in the

UTM rent- -

5Data acquisition

unit-PCI control card100 1 100

6MFC FBG Sensor

Interrogator-rent200 1 Set 200

7 Total NA 1 525

Analytical VerificationModel 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

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

Sensitivity Analysis

= 1.675e-13

= 6.05e-13

Parametric Study

• Response Variable: Maximum Equivalent (von-Mises) Stress

Conclusion

Recommended Column:• 11% Hexagonal Infill• 0° Infill Angle

Maximum Stress• 15.76 MPa

Mass• 27.88 mg