Ultem(R)ate Bracket C2 (0.021 lbs, 0.440 cu in)

grabcad

These ultra-lightweight brackets weigh just 0.021 lbs and have a volume of 0.440 cubic inches each. Attach them to your launch vehicle using two bolts per bracket. The design employs common 3D printing techniques to minimize the mass of unstressed but thick parts (bosses). All stresses are under 4,500 psi; a singularity/stress riser caused by bolt-bracket contact was analyzed analytically to determine the correct contact pressure and Hertzian stresses. No optimization was necessary since preliminary sizing was done using basic mechanical principles and then verified through FEM analysis. The brackets can be printed without support structures, and an elastic hinge allows for easy alignment during vehicle mounting. Tools have ample space to access the bolts. A 15% infill density is used in unstressed areas to further reduce mass. An extra load case considers a 14.7 psi differential pressure inside the infill volume to prevent bracket breakup during ascent. For more details, review the attached PDF file detailing calculations and design considerations. A picture illustrating stress distribution differences between real contact and bonded contact is included for reference. Best regards, Wilbert Engels