Design of Experiments for drop tower impact and tensile welding of 3D printed structures

Two studies were conducted during this EYRCM program project; Drop Tower Impact of 3D printed structures and welding studies of 3D printed structures. Most recommendations for fused deposition method (FDM) 3D printer settings revolve around the final aesthetic of the part and do not focus on the strength of the part created. FDM 3D printed parts are typically quite weak in the vertical direction and can be prone to significant damage from impacts. A design of experiments (DOE) was used to determine which settings used to print the part have the greatest effect on the final appearance and impact strength of the part. Flat panels were printed and a drop tower impact test was conducted on the specimens. JMP was then used to statistically analyze the effects of the DOE. Additionally, several methods were explored to weld together 3D printed parts. Tensile testing was conducted to compare the weld joints, and it was determined that strong, effective welds can be attained with simple methodology. These studies open doors for new 3D printed designs to be used as final parts and/or allows for the splicing of several 3D printed parts into larger structures like a jigsaw puzzle

sTable Sawhorse: A Compact Folding, Sturdy Sawhorse Designed to be Light Weight And Save Space

The sTable Sawhorse is a composite, clamshell-style folding structure designed to be a mobile set of legs to support and raise objects to an appropriate work height. Designed with space saving in mind while folded, the sawhorse takes up minimal space while not in use. Manufactured with a woven fiberglass c-channel body, epoxy resin, and a foam core, the sTable Sawhorse is lightweight and robust. A large, flat top work surface allows for better contact and control of items placed on it. A wide footprint also allows for a very stable structure. This product is unique in that it combines a light-weight frame with the strength of similar bulkier and heavier alternatives. Consisting of two identical halves, the sawhorse is simple in design and construction. Testing will be conducted to determine the strength and the UV resistance of the legs as well as the overall stability of the structure