[3D Printing Application] Can 3D Printing Filament Really Lift a 12-Ton Tank!? An Amazing Feat by Ultimaker!
"How strong are 3D printed objects?" I believe this is a common question for everyone, especially engineers. After all, understanding what a material 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 to use a tensile testing machine, print a small sample, and apply a strong force until the sample breaks. The force applied at the breaking point divided by the surface area of the central cross-section is the strength coefficient. While these data are significant for engineers, sometimes "seeing is believing." To realize the impressive strength of the 3D printed samples they envisioned, Ultimaker and Covestro, along with the Royal Dutch Navy, embarked on an unprecedented collaboration: to lift something extremely 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 using 3D printed samples, the first step was to analyze the available hardware. The Royal Dutch Navy had a special lifting tank that could be used. The connection method involved steel rings that could open on both sides, with one side connecting to the crane and the other to the cable for lifting the vehicle. The shape 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.
He first defined the design requirements:
. The connecting object needed a flat surface for stable 3D printing.
. The print layers of the connection needed to be aligned with the direction of the force applied to the sample.
. The contact area between the printed sample and the metal steel rings needed to be as large as possible to evenly distribute the force.
Finding the Right Material
There are hundreds of filaments compatible with Ultimaker, each with a unique combination of properties, making it highly probable to meet the design requirements. Additionally, the filament itself had to be extremely strong and capable of absorbing short peak forces. Covestro's Addigy® F1030 CF10 met these requirements perfectly. This nylon-based polymer contains carbon fibers and can be printed using an Ultimaker S5 with a CC print core.
Optimizing the Design with Simulation
Compared to traditional manufacturing methods, 3D printing a robust 2 kg connector takes less time. However, validating the printed sample requires iterative testing. Using computer simulation to optimize the design before printing can effectively save time spent on repetitive testing.
Covestro used software with the physical properties of carbon fiber nylon to digitally apply force to the design. Through simulation calculations, the design could be precisely adjusted, removing unnecessary filament sections. This method optimized the entire design, allowing it to lift more weight with less filament, resulting in faster production times and lower costs.
Validating the Simulation
Before lifting the super-heavy vehicle, the calculated strength of the printed sample needed physical validation. Two designs of two sizes were created: the first was a 1 kg connector, estimated to withstand 12 tons. The second, weighing approximately 2 kg, was estimated to withstand 38 tons. The Royal Dutch Navy had an industrial tensile tester on-site, capable of applying forces up to 343 kN. Both the initial and optimized versions were tested for both large and small sizes.
He first defined the design requirements:
. The connecting object needed a flat surface for stable 3D printing.
. The print layers of the connection needed to be aligned with the direction of the force applied to the sample.
. The contact area between the printed sample and the metal steel rings needed to be as large as possible to evenly distribute the force.
Finding the Right Material
There are hundreds of filaments compatible with Ultimaker, each with a unique combination of properties, making it highly probable to meet the design requirements. Additionally, the filament itself had to be extremely strong and capable of absorbing short peak forces. Covestro's Addigy® F1030 CF10 met these requirements perfectly. This nylon-based polymer contains carbon fibers and can be printed using an Ultimaker S5 with a CC print core.
Optimizing the Design with Simulation
Compared to traditional manufacturing methods, 3D printing a robust 2 kg connector takes less time. However, validating the printed sample requires iterative testing. Using computer simulation to optimize the design before printing can effectively save time spent on repetitive testing.
Covestro used software with the physical properties of carbon fiber nylon to digitally apply force to the design. Through simulation calculations, the design could be precisely adjusted, removing unnecessary filament sections. This method optimized the entire design, allowing it to lift more weight with less filament, resulting in faster production times and lower costs.
Validating the Simulation
Before lifting the super-heavy vehicle, the calculated strength of the printed sample needed physical validation. Two designs of two sizes were created: the first was a 1 kg connector, estimated to withstand 12 tons. The second, weighing approximately 2 kg, was estimated to withstand 38 tons. The Royal Dutch Navy had an industrial tensile tester on-site, capable of applying forces up to 343 kN. Both the initial and optimized versions were tested for both large and small sizes.
The Royal Dutch Navy tested a 2 kg connector, which could withstand 38 tons under normal conditions.
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 the feasibility of this workflow, greatly benefiting both 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 a military base in the southern Netherlands, the Royal Dutch Navy provided an armored recovery vehicle from the 13th Light Armored Brigade for assistance with the test. The test results showed that the 1 kg connector could lift a military-version Mercedes Jeep weighing over 2 tons. Of course, the vehicle was lifted with ease, so a larger test was next!
The 2 kg carbon fiber-reinforced nylon connector was placed between the M113 armored vehicle and the Buffalo crane. The metal steel rings were bolted tightly, and four cables were connected from the hooks below to the tank. The crane slowly began to move upward, putting the cables and the 3D printed connector under maximum tension. The 12-ton tank slowly rose, suspended by the 3D printed connector. The Buffalo moved back and forth, reversed, moved forward, and even changed direction, yet the 3D printed connector held up perfectly! This tripartite collaboration achieved extremely successful results.
A 2 kg 3D printed sample easily withstands a vehicle weight 6000 times its own.
Experience and Key Takeaways
The success of this project was not only due to changes in the workflow, but also because a lot was learned. The simulation capabilities of CAD software are no longer just about a shape; by considering the material and fiber orientation of the filament, it can 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 significant 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 characteristics of the filament and treating it accordingly is crucial.
While technical data sheets provide abstract numerical strengths, actual testing and firsthand observation can lead to a greater understanding of the possibilities of additive technology, and perhaps even inspire unexpected ideas!
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Reference material
The success of this project was not only due to changes in the workflow, but also because a lot was learned. The simulation capabilities of CAD software are no longer just about a shape; by considering the material and fiber orientation of the filament, it can 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 significant 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 characteristics of the filament and treating it accordingly is crucial.
While technical data sheets provide abstract numerical strengths, actual testing and firsthand observation can lead to a greater understanding of the possibilities of additive technology, and perhaps even inspire unexpected ideas!
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 material