DESIGN AND OPTIMISATION ‎OF A LIGHTWEIGHT ‎HOLDER OF THE ZALY MONITORING SYSTEM FOR ‎‎ADDITIVE MANUFACTURING

Abstract

This project focused on designing and optimising a temporary holder for the ZALY monitoring system, ‎produced by the Saudi company the National Company for Mechanical Systems. The objective was to create ‎a holder that is lighter in weight while retaining its essential functional characteristics, enabling on-demand ‎printing in remote areas to bypass supply chain challenges. This aim was achieved by the principles of ‎Design for Additive Manufacturing, Topology Optimisation, and the distributed approach of AM supply ‎chains‏.‏‎ Following the project objectives, a seven-step methodology was introduced, commencing with ‎problem definition and culminating in testing. A key objective was to use Material Extrusion (Fused ‎Deposition Modelling) for the holder’s manufacturing. To pursue this, two thermoplastic polymers, (PLA/PHA) ‎‎and (ABS-M30), were assessed and compared to the current holder’s material. The (PLA/PHA) polymer ‎displays a maximum von Mises stress of (‎187.354×10^-3‎) MPa and a displacement of ‎‎(11.293×10^-3 ) mm, was selected for further vibrational validation before topology ‎optimisation‏.‏‎ The redesigned holder demonstrated remarkable resilience, with a von Mises stress of (4.381) ‎MPa and a displacement of (0.783) mm, achieving a notable (90) % volume reduction. It was subsequently ‎manufactured using the Creality CR-10 Max, utilising (959) g of material at the cost of (£20.45)‎‏.‏‎ However, ‎during the testing phase, an approximately (80) % discrepancy between FEA simulations and actual results ‎‎underscored the intricacies of FDM layer anisotropy, among other factors. The research highlights the ‎criticality of ‎experimental validations, especially when dealing with dynamic loads in challenging terrains, ‎aspects not considered in ‎the vibrational assessment. Despite these uncertainties, the project provided ‎valuable insights into the design of the ZALY ‎system’s temporary holder.‎