Investigating Joint-Free Mechanical Systems with PLA and ABS Materials Using the Fuse Deposition Modelling Method

In recent times, the growing popularity of joint-free mechanical systems and structures is attributed to advancements in 3D printing technology. Unlike traditional mechanically joined systems, 3D-printed products require fewer fasteners. However, the widespread adoption of additive manufacturing in the mechanical industries is hindered by limitations in handling various engineering materials. Currently, only a restricted range of ductile and plastic materials is utilized in additive manufacturing processes. This study aims to replace adhesive bonding and bolt joints with an innovative approach involving equivalent geometrical layers. The strength of these joints is intended to be achieved through careful consideration of layer thickness and geometry. The research investigates the strength of conventional lap joints, such as adhesive-bonded or bolted joints, across different materials. Finite element models of these ASTM specimens will be developed in ANSYS for static analysis and comparison. The ultimate goal is to establish an equivalent design procedure that replaces traditional joints with layers of materials through the additive manufacturing process. To validate this approach, a quadcopter structure was designed using 3D printing technology, fabricated with ABS and PLA materials, assembled, and flight-tested to achieve a thrust-to-weight ratio of nearly two. The successful validation of the design demonstrates that 3D-printed additive manufacturing is a valuable technology for constructing lightweight and high-performance UAV structures. Notably, the quadcopter frame was produced as a single component, streamlining the assembly process compared to traditional assemblies consisting of eight to ten parts.