Unique Presentation Identifier:

P21

Program Type

Undergraduate

Faculty Advisor

Mohammad Amjadi

Document Type

Poster

Location

Face-to-face

Start Date

29-4-2025 9:30 AM

Abstract

Additive manufacturing, commonly known as 3D printing, has revolutionized the production of lightweight, customized, and cost-effective components across various industries. This study specifically investigates the fatigue behavior of two thermoplastics—Nylon and ASA—fabricated using the Fused Deposition Modeling (FDM) technique. These materials have demonstrated significant potential in aerospace applications, particularly for lightweight structural components in mini drones and satellites, where corrosion resistance and high performance are critical requirements. Specimens were manufactured using the state-of-the-art Bambu Lab X1 Carbon printer, and the influence of key printing parameters—such as infill density, layer height, and test frequency—was systematically analyzed under cyclic loading. Among the infill patterns investigated, the Gyroid pattern exhibited superior fatigue performance due to its isotropic mechanical properties and optimized strength-to-weight ratio. Additionally, the study revealed that higher infill densities contributed to increased fatigue life, while variations in testing frequencies provided insights into material behavior under dynamic loading conditions. These results were consistent with the behavior observed in conventionally manufactured injection-molded specimens, affirming the viability of 3D-printed components in demanding aerospace environments.

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Apr 29th, 9:30 AM

Fatigue Behavior of 3D-Printed Nylon and ASA for Aerospace Applications

Face-to-face

Additive manufacturing, commonly known as 3D printing, has revolutionized the production of lightweight, customized, and cost-effective components across various industries. This study specifically investigates the fatigue behavior of two thermoplastics—Nylon and ASA—fabricated using the Fused Deposition Modeling (FDM) technique. These materials have demonstrated significant potential in aerospace applications, particularly for lightweight structural components in mini drones and satellites, where corrosion resistance and high performance are critical requirements. Specimens were manufactured using the state-of-the-art Bambu Lab X1 Carbon printer, and the influence of key printing parameters—such as infill density, layer height, and test frequency—was systematically analyzed under cyclic loading. Among the infill patterns investigated, the Gyroid pattern exhibited superior fatigue performance due to its isotropic mechanical properties and optimized strength-to-weight ratio. Additionally, the study revealed that higher infill densities contributed to increased fatigue life, while variations in testing frequencies provided insights into material behavior under dynamic loading conditions. These results were consistent with the behavior observed in conventionally manufactured injection-molded specimens, affirming the viability of 3D-printed components in demanding aerospace environments.