ULA Bracket 2 Parts

grabcad

This design of the ULA Bracket is both weight-optimized and 3D print friendly, requiring minimal support material. To reduce weight further and eliminate support needs, I chose to create two separate parts instead of one. The screw surfaces of the lower and upper holes are positioned close to the walls, reducing screw length and thus weight. Since the lower hole experiences high stress (up to 4500 PSI), steel inserts are recommended post-printing. Optimized relief grooves have been added to mitigate the notch effect. The minimum hole diameter is 4 times its size. High-resolution FEM simulations demonstrate that a load of 600 lbf (300 per part) results in a maximum stress of 4430 PSI, well below the 4500 PSI limit. Ensure optimal printing direction for higher strength: Weight = 0.134 lb (0.067 lb per part); Volume = 2.772 in^3 (1.386 in^3 per part). Thank you for the challenge, and good luck to all participants!