Manufacturing and characterization of compliant Cardan joints obtained by a new combined fabrication process

Abstract The Cardan joint is a key component in many applications. It comprises a number of mechanical elements properly assembled. Building Cardan joints in a single monolithic element using 3D-printing and compliant hinges (CHs), could be economically advantageous. Some applications, especially related to small devices, required small sized Cardan joints. However, the construction of CHs becomes inefficient when their CH size is comparable with that of the extruded filament of the 3D printer. Based on a recent manufacturing process called 3D-PLAST, this drawback can be overcome and CHs of small dimensions can be obtained. Compliant Cardan joints with small dimensions (with external diameters of 4 and 6 mm) have been manufactured by this recent process. This paper presents the kinematic and stiffness performances of these joints to highlight their feasibility and efficiency for small-size system applications.