Investigating on 3D printing technologies on customised sensor

As Additive manufacturing is getting more attention these days, there is an increase interest in printing electronics. A study of 3D printing technologies and basic electronics such as strain gauge were covered in this project. Since strain gauges are widely used in various industries, there is a possibility in customizing sensors for failure mode and effect analysis. Comparisons between Inkjet and Aerosol Jet were discussed, and Aerosol Jet was selected in this project to print the strain gauges for experiment. An optimization of process parameters was done using design of experiment to eliminate the insignificant parameters. The two most significant parameters have a great impact on the output response of line width with varying profile shown. A further selection of parameter experiment was done to print desired line width to obtain desired resistance. The line width and resistance have an interrelation of inverse proportional to the desired results. Design and experiment considerations were mentioned and emphasised that every part plays a role in obtaining good printing results. A commercial strain gauge FLA-5-11 120 Ω from TML was bought for comparison with a similar modelled 3D printed strain gauge. Low cost FDM printing of tensile coupons were needed as a specimen to install the 3D printed strain gauge on it for experiment. With the installation of strain gauges done, the experiment was carried out with Shimadzu AG-X deflection test and three-point bending test. Both commercial and 3D printed strain gauge were measured using LabVIEW and NI instrument for change in resistance measurement. Comparisons between commercial and 3D printed strain gauge were discussed in this project. 3D printed strain gauges showed similar trends, under tension its resistance increases and under compression its resistance decreases. 3D printed strain gauges are highly sensitive and can detect the slightest change in displacement.Bachelor of Engineering (Mechanical Engineering