Experimental Comparison of Fastener Implementation Approaches in Fused Deposition Modeling

Abstract

Featured Application Additive manufacturing is frequently used in industries that require the manufacturing of special parts, such as aerospace, automotive, medical, and situations where the produced parts need to be connected to each other. This study provides experimental data for integrating fasteners into additive manufactured parts, and the results will guide the design and optimization of the assembly of these parts.Abstract This study aims to investigate common fastener implementation methods for parts manufactured with Fused Deposition Modeling (FDM). Although fastener applications for FDM manufactured parts are already in use, the effects of these methods on tensile and bending forces have not been examined. Test samples with different design techniques and infill ratios were produced using Polylactic Acid (PLA), and tensile strength and flexural and tightening torque tests were performed. Four of the of the most preferred fastener applications were studied. Two of the applications use a heat-set insert, and the other two applications use square nuts. Test samples were designed for the applications and printed with three different infill ratios. The production times and material consumption for these different applications were explained and evaluated. Different drawbacks and advantages were investigated for different applications. It has been observed that the strength of the basic heat-set inserts depends on the surface adhesion and is less affected by the filling rate. Advanced heat-set inserts adhere better to the surface, so the infill ratio is the determining factor in strength. The embedded nut methods depend on the infill ratio up to a certain load. As the load increases, the influence of wall thickness becomes increasingly evident. These findings not only contribute to enhancing structural integrity but also offer invaluable insights into optimizing connection methods for diverse applications.