Additive Manufacturing

Additive manufacturing (AM) or additive layer manufacturing (ALM) is the industrial production name for 3D printing, a computer controlled process that creates three dimensional objects by depositing materials, usually in layers. 

Roller Chain Modeling Challenge

Overview: Over the course of four class periods, your task is to design and 3D model a roller chain link of your own creation. The final goal is to print a series of five interconnected links, ensuring that the chain moves freely like a traditional roller-type chain. Importantly, your design must be printable without the use of slicer-generated supports.

Design and Manufacturing Criteria:

• All modeling must be completed in SolidWorks.

• Prepare your design for 3D printing using a slicer compatible with additive manufacturing.

• Use PLA filament for all prints.

• Each individual link must occupy no more than 20mm cube of space.

• Conduct test prints with a maximum of two links before proceeding to the full print (up to five links).

• Slicer-generated supports are not permitted; your design must be self-supporting.

Presentation Requirements:

• Upload your work to your Additive Manufacturing page on your ePort.

• Challenge instructions (this document) must be clearly displayed for viewers to understand the task (20% of grade).

• Include images and GIFs showcasing your modeling and design process, including yellow preview renders of both individual links and the assembled chain in SolidWorks and during 3D printing (40%).

• Provide ePort posts with images of notebook sketches, GIFs of modeling in SolidWorks, slicer screenshots, and any additional relevant information (20%).

• Present your final design as a GIF showing the completed chain moving in your hands (20%).

Tips for Success:

• Focus on designing links that interlock and articulate smoothly, while remaining within the size constraint.

• Test your design for printability and movement before committing to the full chain.

• Document your process thoroughly with visuals and notes to support your presentation.

By following these guidelines, you will demonstrate your skills in CAD modeling, additive manufacturing, and iterative design.