Additive Manufacturing of Thermoplastic M8 Fasteners Using Photopolymer Jetting Technology for Low-Strength Fastening Applications
Abstract This study investigates the spatial accuracy of additively manufactured M8 fasteners fabricated using photopolymer jetting technology. A number of M8 bolts and their mating M8 nuts are fabricated using Stratasys Object 260 Connex 3 polyjet printer with Vero cyan, Vero magenta, Vero white, and Vero grey thermoplastic resins. Vero series thermo-plastics were used as they offer durability, strength, and flexibility. The additively manufactured nuts and bolts are fabricated with the intention of introducing thermoplastic fasteners that could eventually substitute metal fasteners in certain low strength joining applications such as in fluidics, electronics, biomedical engineering, food packaging, and automobile industries. Manufacturing constraints and critical conditions for fabrication are presented. Vital printing and manufacturing constraints, dimensional stability analysis, and the subsequent dimensional changes for the fabricated fasteners are thoroughly illustrated. Dimensional stability of the printed structures was examined under an ultra-compact 3D laser sensor and the imaging results are also presented. The fabricated thread profile superimposed precisely with the CAD model’s ISO thread profile dimensions. The dimensional performance of the fabricated M8 fasteners was examined in every orientation and along each axis of the fasteners. The high-quality manufacturing of fasteners using photopolymer jetting reached the maximum precision requirements and fitted under IT 06 transition fit grade.