GE Challenge - Charlie Pyott

grabcad

4.52 lbs., 2051 g, 28.27 in³ - Original Design Lattice Type 1 (Early Test Design): - Pyott_Type1Lattice (STEP, SW versions) - 0.89 lbs., 408 g - 5.62 in³ Solid Type 2: - Pyott_Type2Solid (IGES, STEP, SW versions) - 0.97 lbs., 439 g - 6.05 in³ (78% improvement compared to Lattice Type 1) Lattice Type 2: - Pyott_Type2Lattice (IGES, STEP, SW versions) - 0.85 lbs., 386 g - 5.32 in³ (81% improvement compared to Lattice Type 1) Simulation Results Notes: - Original design concept focused on lateral sweeping from attachment bolts to pin, promising results with fixed geometry simulation - Revisiting the design using actual 3D geometry as interference objects led to stress around interface 2-5 increasing from 90 KSI to 300 KSI+ - Design evolved to distribute load more evenly across bolt heads - Maximum KSI for loading condition 1 is 152 with uniform meshing, reduced to 111 with custom high-density mesh conditions around interfaces - Discussed simulation challenges on parts with tight tolerances Lattice Version and Rule Concerns: - Included lattice versions as a design entry, pushing the edge of design and potential of 3D printing - Lattice version has knife-edges under 0.050 in minimum material feature size, questioning its compliance with rules due to wording interpretation Lattice Version and Simulation Challenges: - Unable to obtain a valid simulation solution due to geometry complexity - No idea how lattice version would behave as a DMLS part under actual loading, offering that it should work and be fun to find out Website: www.pyottdesign.com