3D Printed ABS Cantilever Bridge
3D Printed ABS Cantilever Bridge
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Project Summary
I worked with a team of 5 to design and 3D-print a cantilevered structure optimized for maximum load capacity under strict geometric and mounting constraints. We developed and iterated on multiple design concepts in SolidWorks, running finite element analysis to map stress distributions, pinpoint failure-critical regions, and inform our material placement strategy.
I focused on refining the geometry by strategically removing material from low-stress zones while reinforcing high-stress areas, applying truss and I-beam principles to maximize structural efficiency. I also contributed to the nonlinear FEA work, helped determine optimal print orientations to align layer strength with load paths, and worked through fabrication planning to bridge the gap between simulated and real-world performance. The result was a highly optimized design that performed well in competition.
Design Requirements
Volume Limitations: Must not use more than 2 cubic inches of total filament
Mounting: Mounted on standard slot pattern with pre-specified 1/4" - 20 hardware
Performance: Holds the most weight possible, 6" horizontally from mounting holes
Project Details
Year: 2025
Duration: 5 weeks
Software: SolidWorks, Fusion 360, BambuStudio
Materials: ABS Plastic
FEA Simulation
To predict the maximum load and failure location of the structure, linear and nonlinear FEA were utilized. We took advantage of both Fusion 360 and SolidWorks FEA, comparing results and using them to inform decisions about design iterations. The final design was based on the load paths of a topology-optimized cantilever beam.
Performance Prediction
By analyzing our FEA results and taking print defects into account, we predicted a max failure load of 90 lb. The bridge failed under a load of 100 lb, representing an 11% variance from the actual load. We also predicted the bridge to fail at the hook, since the load from the weight hanger was to be concentrated there.
Validation and Final Results
The bridge conformed to all rules and regulations
The bridge yielded at 100 lb., which was the 4th highest out of 25 teams
We predicted one of the failure points of the structure correctly
Nonlinear FEA of the final design
Bridge after breaking in testing
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