Review and preliminary design of 3-D printed ABS polymer torsion element with parametric internal structures

Abstract

Various components utilized in the automobile dashboard controls are manufactured from plastic by a conventional molding process. With the recent trend and continuously changing designs of the compo- nents due to frequently upgraded models, the conventional process of manufacture of these components proves costly owing to the high investment in molds. The technology which has taken attention for these demanding conditions is the Fused Deposition or 3-D printing technology in development and manufac- ture of plastic components for ready use direct assembly which bypasses the process of mold manufac- ture and then subsequent plastic molding which is many times involves a considerable amount of production time and high production cost. The strength of the components produced by the 3-D printing method is seen to be greatly influenced by the infill density, print quality, and layer thickness. The depositing parameters have been studied in various studies but they failed to characterize the geo- metrical arrangement permutations through the addition of internal support structures to enhance the torsion strength of the components. The paper discusses a review of research work over the years pro- poses the first stage design and analysis of the plain component using Ansys workbench and also the manufacturing of these plain elements with various permutations of infill density, layer thickness, and print quality. The components thus produced will be tested and compared for optimal deposition param- eters. By considering the gathered data, an optimization model that realizes the material usage, build time, strength characteristics, and their related variables will be presented and used to assist the compo- nents with optimal deposition parameters which will be further considered for design with internal sup- port structures with the incorporation of varied parametric internal structure matrix. Ó 2023 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 2nd International Con- ference and Exposition on Advances in Mechanical Engineering.