【3D Printing Application】Can 3D Printing Filament Lift a 12-Ton Tank!? An Amazing Feat by Ultimaker!
"How strong are 3D printed objects?" This is probably a common question for everyone, especially engineers. After all, understanding what materials can be used for is crucial. Ultimaker, Covestro, and the Royal Dutch Navy came together to brainstorm and find the answer!
The usual way to test material strength is with a tensile testing machine, printing a small sample and applying great force until the sample breaks. The force applied at breakage divided by the surface of the central cross-section gives the strength coefficient. While these data are significant for engineers, sometimes "seeing is believing." To realize the immense strength of 3D printed samples imagined in their minds, Ultimaker and Covestro, along with the Royal Dutch Navy, embarked on an unprecedented collaboration: to lift something very heavy! Was it a super-heavy dumbbell, a motorcycle, a car, or a jeep?
The Royal Dutch Navy proposed, "Why not try an armored vehicle?"
This suggestion captured everyone's imagination!
The Royal Dutch Navy proposed, "Why not try an armored vehicle?"
This suggestion captured everyone's imagination!
Initial Design Creation
To lift a super-heavy vehicle with a 3D printed sample, the available hardware first needed to be analyzed. The Royal Dutch Navy had a special lifting tank that could be used. The connection method involved steel rings that could be opened on both sides, with one side connecting to a crane and the other to the cable lifting the vehicle. The design was an elongated O-shaped link capable of connecting two metal steel rings and lifting super-heavy vehicles.
After importing the geometry of the metal steel rings into CAD software, Ultimaker application engineer Lars de Jongh became the initial designer.
First, he defined the design requirements:
．The connecting object needs a flat surface for stable 3D printing.
．The print lines for the connection must align with the direction of the force applied to the sample.
．The interaction surface between the printed sample and the metal steel ring should be as large as possible to evenly distribute the force.
Finding the Right Material
There are hundreds of compatible filaments that can be used with Ultimaker, each with a unique combination of properties, most likely meeting the design requirements. Additionally, the filament itself must be very strong and able to absorb short peak forces. Covestro's Addigy® F1030 CF10 perfectly met these requirements. This nylon-based polymer contains carbon fiber and can be printed with the Ultimaker S5 and CC print core.
Optimizing Design with Simulation
Compared to traditional manufacturing methods, 3D printing a rigid 2kg connector takes less time. However, verifying the printed sample requires iterative testing. Optimizing the design with computer simulations of real objects before printing can effectively save time spent on repeated testing.
Covestro used software with the physical properties of carbon fiber nylon to digitally apply force to the design. By running simulations, they could precisely adjust the design, removing unnecessary filament areas. This method optimized the entire design, allowing it to lift more weight with less filament, resulting in faster production times and lower costs.
Verifying Simulation
Before it could lift super-heavy vehicles, the calculated strength of the printed samples needed physical verification. There were two designs in two sizes: the first was a 1kg connector, estimated to withstand 12 tons. The second, weighing approximately 2kg, was estimated to withstand 38 tons. The Royal Dutch Navy had an industrial tensile tester on site, capable of applying up to 343 kilonewtons of force to objects. Both the original and optimized versions were tested for both large and small sizes.
First, he defined the design requirements:
．The connecting object needs a flat surface for stable 3D printing.
．The print lines for the connection must align with the direction of the force applied to the sample.
．The interaction surface between the printed sample and the metal steel ring should be as large as possible to evenly distribute the force.
Finding the Right Material
There are hundreds of compatible filaments that can be used with Ultimaker, each with a unique combination of properties, most likely meeting the design requirements. Additionally, the filament itself must be very strong and able to absorb short peak forces. Covestro's Addigy® F1030 CF10 perfectly met these requirements. This nylon-based polymer contains carbon fiber and can be printed with the Ultimaker S5 and CC print core.
Optimizing Design with Simulation
Compared to traditional manufacturing methods, 3D printing a rigid 2kg connector takes less time. However, verifying the printed sample requires iterative testing. Optimizing the design with computer simulations of real objects before printing can effectively save time spent on repeated testing.
Covestro used software with the physical properties of carbon fiber nylon to digitally apply force to the design. By running simulations, they could precisely adjust the design, removing unnecessary filament areas. This method optimized the entire design, allowing it to lift more weight with less filament, resulting in faster production times and lower costs.
Verifying Simulation
Before it could lift super-heavy vehicles, the calculated strength of the printed samples needed physical verification. There were two designs in two sizes: the first was a 1kg connector, estimated to withstand 12 tons. The second, weighing approximately 2kg, was estimated to withstand 38 tons. The Royal Dutch Navy had an industrial tensile tester on site, capable of applying up to 343 kilonewtons of force to objects. Both the original and optimized versions were tested for both large and small sizes.
The Royal Dutch Navy tested the 2kg connector, which under normal conditions could withstand 38 tons of weight.
The optimized version could withstand more force while being one-third lighter. The difference between the test results and simulation data was also very close, with an average error of 1%. This proved that such a workflow is feasible, greatly benefiting time-to-market and performance improvement.
Lifting Two Vehicles
After months of design, printing, testing, and planning, it was time for the lift! Two connectors were about to lift a real military heavy vehicle. At the army base in southern Netherlands, the Royal Dutch Navy provided an armored recovery vehicle from the 13th Light Rhino Brigade for assistance with the test. The test results showed that the 1kg connector could lift a military-spec Mercedes Jeep weighing over 2 tons. Of course, the vehicle was easily lifted; next was a larger test!
A 2kg carbon fiber reinforced nylon connector was placed between an M113 armored vehicle and a Buffalo crane. The metal steel rings were tightened, and four cables connected the hooks below to the tank. The crane slowly began to move upward, putting the cables and the 3D printed connection under maximum tension. The 12-ton tank slowly rose, suspended by the 3D printed connection. The Buffalo moved back and forth, reversed, moved forward, and even changed direction, yet the 3D printed connection held perfectly! This three-way collaboration yielded very successful results.
A 2kg 3D printed sample easily withstands a vehicle weighing 6000 times its own weight.
Experience and Key Takeaways
The success of this project was not only due to changes in workflow; much was learned as well. CAD software simulations are no longer just about shapes, but now consider the filament material and fiber direction to provide accurate predictions, making it a very powerful tool for engineers!
Although all printed objects were printed indoors with well-controlled temperature and humidity, and the filament was not exposed to moisture, there was a noticeable difference between versions printed in a dry warehouse and those printed in a heated, dry print chamber using specially dried spools. Nylon absorbs moisture, which can make the printed product brittle, so understanding the filament's characteristics and handling it accordingly is crucial.
While technical specifications provide abstract numerical strengths, actual testing and firsthand observation can lead to a deeper understanding of the possibilities of additive technology, and perhaps even unexpected inspiration!
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Reference
The success of this project was not only due to changes in workflow; much was learned as well. CAD software simulations are no longer just about shapes, but now consider the filament material and fiber direction to provide accurate predictions, making it a very powerful tool for engineers!
Although all printed objects were printed indoors with well-controlled temperature and humidity, and the filament was not exposed to moisture, there was a noticeable difference between versions printed in a dry warehouse and those printed in a heated, dry print chamber using specially dried spools. Nylon absorbs moisture, which can make the printed product brittle, so understanding the filament's characteristics and handling it accordingly is crucial.
While technical specifications provide abstract numerical strengths, actual testing and firsthand observation can lead to a deeper understanding of the possibilities of additive technology, and perhaps even unexpected inspiration!
Did you enjoy this sharing? 3DMart offers more than just 3D printing. Contact us now to learn more about 3D printers and 3D scanners.
Follow our fan page for updates: https://www.facebook.com/3dmart.com.tw/
https://www.instagram.com/3dmart/
Reference