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University of Texas at El Paso DigitalCommons@UTEP Open Access Theses & Dissertations 2013-01-01 The evelopmeD nt of Self-Supported Electromechanical Structures Using Fused Deposition Modeling Jorge Ramos-Almeida University of Texas at El Paso, [email protected] Follow this and additional works at: https://digitalcommons.utep.edu/open_etd Part of the Mechanical Engineering Commons Recommended Citation Ramos-Almeida, Jorge, "The eD velopment of Self-Supported Electromechanical Structures Using Fused Deposition Modeling" (2013). Open Access Theses & Dissertations. 1714. https://digitalcommons.utep.edu/open_etd/1714 This is brought to you for free and open access by DigitalCommons@UTEP. It has been accepted for inclusion in Open Access Theses & Dissertations by an authorized administrator of DigitalCommons@UTEP. For more information, please contact [email protected]. THE DEVELOPMENT OF SELF-SUPPORTED ELECTROMECHANICAL STRUCTURES USING FUSED DEPOSITION MODELING JORGE RAMOS-ALMEIDA Department of Mechanical Engineering APPROVED: Ryan B. Wicker, Ph.D., Chair Norman Love, Ph.D. Eric MacDonald, Ph.D. Benjamin C. Flores, Ph.D. Dean of the Graduate School Copyright © by Jorge Ramos-Almeida 2013 Dedication I would like to dedicate my thesis to my parents and sister, who have encouraged and supported me throughout my education THE DEVELOPMENT OF SELF-SUPPORTED ELECTROMECHANICAL STRUCTURES USING FUSED DEPOSITION MODELING by JORGE RAMOS-ALMEIDA, B.S.M.E. THESIS Presented to the Faculty of the Graduate School of The University of Texas at El Paso in Partial Fulfillment of the Requirements for the Degree of MASTER OF SCIENCE Department of Mechanical Engineering THE UNIVERSITY OF TEXAS AT EL PASO December 2013 Acknowledgements I would like to express my sincere gratitude to my advisor Dr. Ryan Wicker, Director of the W.M. Keck Center of 3D Innovation for allowing me to perform the research presented in this thesis. Thanks to his valuable guidance and constructive comments throughout my research projects I completed as a graduate student. I also wish to thank Dr. Francisco Medina, former manager of the W.M. Keck Center for 3D Innovation for believing in me and allowing me to be part of this wonderful group of people. Mr. David Espalin, current manager of the W.M. Keck Center for 3D Innovation who also served as a mentor and highly encouraged me to never give up when things seemed difficult. My most sincere appreciation goes to Mr. Efrain Aguilera for assisting me throughout the research of my thesis. Additionally, I would to thank my committee members, Dr. Norman Love and Dr. Eric MacDonald for spending their valuable time assisting me with my research and serving on my committee. To everyone directly involved in the activities of the W.M. Keck Center, my deepest appreciation goes out to them. Finally, I would like to thank my parents, Jorge Ramos, and Martha Ramos and sister Ayla Ramos, for supporting me and encouraging my higher education pursuits. v Abstract Recent research has focused on the fabrication freedom of 3D printing to create not only conceptual models but also final end-use products. In the last decade, several research groups have reported embedding electronic components and electrical interconnects into 3D printed structures during process interruptions; however, to date there is an absence of fabricated devices with electromechanical functionality for parts fabricated in a single Additive Manufacturing (AM) build sequence. The focus of this research is the use of Fused Deposition Modeling (FDM) to manufacture a self- supported electromechanical motor. FDM is an AM process capable of building parts in a layer-by-layer fashion. A uPrint SE Plus (Stratasys, Edina, Minnesota) (a relatively low-cost FDM system), was used to manufacture an electromechanical device. Economical, out-of-the-shelf electrical and mechanical components were used to fabricate the device. A three-phase brushless direct current (DC) motor was chosen because of its easy assembly and minimal requirement of electrical and mechanical components. The motor requires electromagnets, permanent magnets (PM), an electronic speed controller, and ball bearings to function. The three-phase brushless DC motor was manufactured in a process interrupt method where pauses during fabrication were strategically place during the build for the embedding of the electrical and mechanical components. Furthermore, surfaces angled at 45-degrees from horizontal were used in the design to prevent the deposition of internal support material and prevent thermal shock of the electronic components. The three-phase brushless DC motor was designed using an iteration process. The first iteration worked as a proof-of-concept while the second design contains improvements including reduction of mass, fabrication time, and size. The iteration process on the design was done to determine the performance improvements that can be achieved. Thus, the second and final iteration successfully reduced the fabrication time by 2hours (26%), mass by 60g (40%) and size by 40 cm3 (40%) vi Table of Contents Dedication ............................................................................................................................. iii Acknowledgements ................................................................................................................. v Abstract .................................................................................................................................. vi Table of Contents ................................................................................................................. vii List of Tables ......................................................................................................................... ix List of Figures ......................................................................................................................... x Chapter 1 Introduction ...................................................................................................... 1 1.1 Background ........................................................................................................ 1 1.2 Motivation .......................................................................................................... 3 1.3 Thesis Objectives ............................................................................................... 4 1.4 Thesis Outline .................................................................................................... 5 Chapter 2 Literature Review .......................................................................................... 6 2.1 Introduction ........................................................................................................ 6 2.2 Fused Deposition Modeling (FDM) .................................................................. 7 2.3 Embedding of Electronic Components. ........................................................... 16 2.4 Electrical Motors ............................................................................................. 18 2.5 Conclusion ....................................................................................................... 19 Chapter 3 Model and Design of a Self-Supported Electromechanical Structures ....... 21 3.1 Introduction ...................................................................................................... 21 3.2 Material and FDM Selection ........................................................................... 22 3.3 First Iteration Design ....................................................................................... 27 3.4 Second Iteration Design ................................................................................... 44 Chapter 4 Manufacturing the second iteration design motor .......................................... 54 4.1 Introduction ...................................................................................................... 54 vii 4.2 Catalyst EX ...................................................................................................... 55 4.3 Embedding of Components ............................................................................. 56 Chapter 5 Results and Conclusions ............................................................................. 60 5.1 Introduction ...................................................................................................... 60 5.2 Results.............................................................................................................. 60 5.2.1 Mass, Size, Build Time, and Distance ................................................. 60 5.2.2 Constant Angular Velocity, Current and Load Analysis ..................... 61 5.3 Conclusions...................................................................................................... 64 5.4 Recommendations and Future Work ............................................................... 65 References ............................................................................................................................. 66 Appendix A-Torque Equations ............................................................................................. 72 Appendix B-Capacitive Sensor Code ................................................................................... 75 Appendix C-Embedded Electrical and Mechanical Components ........................................ 79 Appendix C.1 Mechanical Components ......................................................

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