Tensegrity Launch Tubes and Compliant Mechanisms for Mechanical Versatility in Small-Scale Industrial Line Launchers: A Reliability-Centered Screening Analysis

This study investigated the integration of 3D-printed tensegrity launch tubes and compliant mechanism components into small-scale industrial line launcher systems. A multi-variable experimental design (n = 108 replicate shots) evaluated a seven-segment PLA tensegrity tube, the potential for a monolithic compliant launcher, and a pneumatic benchmark across various projectile types, tube configurations, and muzzle rifling geometries. The system exhibited a severe 57.4% launch failure rate, with failures concentrated in extended tube configurations and Rigid or Compliant muzzle attachments. To isolate the dominant operational drivers across the dataset, a composite velocity score was analyzed. Non-parametric variance testing identified tube configuration as the primary factor influencing velocity (Kruskal–Wallis H = 26.73, p < 0.001), followed by muzzle geometry (H = 10.20, p = 0.017). Post-test disassembly identified three distinct failure modes, primarily driven by bore clearance rather than the vibrational compliance of the tensegrity architecture. A Failure Mode and Effects Analysis (FMEA) quantified these risks, identifying tensegrity tube bore constriction as the primary threat to system reliability (Criticality = 336). Process capability analysis against Stage 1 prototyping gate criteria confirmed the system is not yet process-capable. Furthermore, a Total Cost of Ownership (TCO) analysis yielded an estimated US $8.07–11.22 per successful launch, challenging the economic scalability of low-cost additive manufacturing materials. This study establishes quantitative benchmarking and a reliability-centered Design for Additive Manufacturing (DfAM) framework required before scaling toward maritime, emergency, or aerospace applications.