An Approach for Designing 3D-Printed Assembled Rotational Joints and Assemblies for Mechanisms and Robot Models

Three-dimensional printing has enabled the production of complex parts that are difficult to create with conventional manufacturing methods. Its additive nature has made it possible to create interconnected (assembled) parts in a single manufacturing step. This requires the development of new ways of designing, manufacturing, and testing mechanisms that do not require assembly after their creation, called non-assembly mechanisms. An approach is proposed for the design and experimental study of the properties of rotational joints created already assembled using FFF technology for 3D printing. The advantages and disadvantages of different 3D printing methods that can be used to obtain such assemblies are discussed. Basic principles for the design of assembled rotational joints, built without support structures, are introduced. Two examples of their application in creating functional robot models are presented. The features during production, and the advantages and disadvantages of the models are discussed. Models of directly assembled rotational joints with different clearances are studied, and an experiment is conducted based on measuring the magnitude of the current during the rotation of a link. This provides indirect results for the rolling resistance, on the basis of which the qualities of the joint are judged. The results from the experiments show that rotational joints with a diameter d = 10 [mm], created using FFF technology and PLA material, have the lowest resistance at a clearance in the range t = 0.15–0.25 [mm].