Embedded Files
Exploring Applications of FDM 3D Printing for a Formula Student Impact Attenuator
Exploring Applications of FDM 3D Printing for a Formula Student Impact Attenuator
In my undergraduate project, I combined my interests of Formula Student, Non-Linear FEA and 3D Printing, to try and create a 3D printed Impact Attenuator.
In the project I used Ansys' Explicit Dynamics module to simulate over 80 drop tests on various structures, optimised for FDM printing technologies.
Structural Testing
Structural Testing
A large section of the report was evalating different geometries, for both their energy absorbing capabilities, and their manufacturability through 3D Printing.
I simulated drop tests on different 2D geometries to begin with, and compared the enegy absorption capabilities of the structure in verious different material options. This enabled me to compare the energy absorbed by each material and each structure.
Following this I tested different 3D geometries, and found that the energy absorbed was far greater than their 2D counterparts, and I developed several structures.
The final concept was to create a stong and uncomprimised strucutre, and the energy-absorption element would be the individual layers failing and crushing.
I learned a lot about non-linear simulation during this project, and performed over 60 different analyses, with an estimated 500 hours spent solving on my poor laptop!
Stellated Octahedron Structure
Stellated Octahedron Structure
The structure that I selected was a stellated octahedron, which is a structure comprised entirely of tetrahedrons, making it strong and suitable for 3D Printing.
This is one of the preliminary simulations that I conducted, showing the way that a stellated octahedron would deform in a drop test.
Energy - Displacement Graph
Energy - Displacement Graph
The energy-displacement graphn was a part of the Impact Attenuator Report that had to be completed for the competition. The relative linearity of the results was promising, and the report was optimistic in terms of the possiblity of using 3D Printing technologies for this use case.
Page updated
Report abuse