Bike Pedal Example of Methodology for 3D-Printed Part Design: Difference between revisions

1) Is there an existing demand for the part or product? If yes, is there improved viability, feasibility, desirability or sustainability with 3-D printing?

  Yes, there is an existing demand. Black mamba bikes ridden in East Africa are often ridden without pedals because the existing pedals fail.  Replacements to existing pedals often needed, but not readily available.

Viable

  Yes, a 3D printing service bureau could sell replacement pedals in East Africa.

Desirable

  Yes, pedals are desired by those who do not have working pedals.

Feasible

  Yes, it is technically feasible to print a bike pedal.

2) Is there an existing offering/part made by traditional manufacturing processes?

  Yes.

If Yes, is there a benefit to 3-D printing the part? (e.g. geometry complexity, customization, density, rapid prototyping, reduce lead times, or unique 3D printing material)?

  A pedal could be 3D printed in a remote location where there are not existing pedals for sale.

3) Is it feasible to 3D print part?

Is the the volume of part less than the build envelope?

  Yes, a pedal is approximately 400 cubic centimeters and the build envelope for the MOST Delta has a 25cm diameter and a 24cm high cylinder.

Is the maximum operating temperature range for part less than the glass transition temperature for the printing filament?

  Yes, the highest recorded temperature recorded in Kenya is 42.5 degrees C, while the glass transition temperature for PLA is between 50 and 60 degrees C.

4) Is there an existing CAD Model or STL file for part?

  Yes, Black Mamba Bike pedal.

5) Determine and quantify necessary mechanical properties, standards, and loads for part.

The following testing methods and standards are given by SASO ^[1].

 Pedal-spindle impact test. Release 15kg from 200mm to strike pedal and spindle.

 Pedal-spindle - dynamic durability test. 100,000 revolutions at 100 per min with 30kg mass attached to tension spring.

 Static strength test.  Apply vertical downward force of 700N to pedal for 1 min.

6) Prioritize necessary mechanical properties, standards, and loads for part.

 Static strength test was selected due to simplicity.  The vertical downward force was increased to 1000N for simulation.

7) Model existing part or prototype.

 OpenSCAD was selected among the opensource software packages.
 
 STL Files for printing: File:Pedal End 1 File:Pedal End 2 File:Pedal Grip 

 Parasolid file for FEA: File:Pedal2.x t
 

8) Conduct Finite Element Analysis (FEA).

 ANSYS was selected for FEA.

 Analysis: Structural
 Element Type: Solid 183 or Solid 187
 Load: 1000N
 Young's Modulus: PLA - 3.5 GPa
 Poisson's Ratio: 0.36
 Mesh:
 

• 

  Pedal Mesh

See also

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