UWE Bristol Engineering showcase 2015

Dom Dececio
Mechanical Engineering (MEng)
Project Supervisor
Jason Matthews PhD
Background Research
A variety of previous research studies were
reviewed covering both Additive Layer
Manufacture (ALM) and Bio-Inspired structures.
The biological structures included bamboo, bone,
honeycomb, nautilus shell and spider’s web
Computer Aided Design (CAD)
Ideas were generated following a background
literature review. This resulted in the creation of
CAD models replicating the associated biological
structures.
Bamboo CAD model
Understanding the process limitations of the Additive Layer
Manufacture Process to support the optimisation of Bio-Inspired
structures
Finite Element Analysis (FEA)
FEA was carried out on all of the CAD models to
identify the strongest models under specific
loading conditions.
Bone CAD model under curved face compression
Fused Deposition Modelling (FDM)
The best performing model following an
evaluation was the bone model. This was
produced using the Universities' Fused Deposition
Modeler, where plastic pellets were melted
through a hot nozzle and precisely layered to form
the desired shape.
FDM produced bone model
Physical Testing & Data Analysis
Once the models were physically produced using
FDM it was possible to compression test and
measure the loads taken by the structures
ABS plastic models under compression in UWE lab
Project Summary
An investigation was carried out in order to establish
the effectiveness of producing biologically inspired
structures using Fused Deposition Modelling (FDM). It
was hypothesised that the direction of the deposited
plastic (build orientation) would have a significant
role in the outcome of the part’s mechanical
performance.
Project Objectives
• Observe the state of the art for current biologically
inspired structures.
• Observe the state of the art for Additive Layer
Manufacture (ALM) techniques.
• Study of a range of biological structures for
possible investigation/development.
• Finite Element Analysis (FEA) to evaluate structural
behaviour including torsion, bending and
compression testing.
• 3D CAD modelling of selected structures, followed
by the creation of Fused Deposition Modelling
prototypes.
• Physical compression tests for comparison against
FEA.
• Creating of an evaluation matrix in order to assess
mechanical properties.
Project Conclusion
• The build orientation has played a key role in the
structures mechanical performance.
• The best performing structure was a model based
on animal bone.
• The best performing layer orientation was in fact
axial to the direction of force in both horizontal
and vertical compression testing.
Nautilus shell model
Iso clipping view showing higher stress regions
Graph showing compression test results