Ashcroft, IanParry, LukeAlzahrani, Mohammed2023-12-262023-12-262023https://hdl.handle.net/20.500.14154/70434This 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.97enDesign for Additive ManufacturingTopology OptimisationDistributed approach of AM supply chainsZALY monitoring systemNational Company for Mechanical SystemsDESIGN AND OPTIMISATION OF A LIGHTWEIGHT HOLDER OF THE ZALY MONITORING SYSTEM FOR ADDITIVE MANUFACTURINGThesis