Towards Printing mechatronics: An optimized battery-powered 3D-printed coupling design

This paper has explored the design considerations pertaining to the 3D printing of a fully autonomous mechatronic device, consisting of an on-board battery powering a standard DC motor without the need of wires or any other classical joining methods. The achieved goal was to make exclusive use of 3D printing to manufacture both the non-conductive geometry of the enclosure and the conductive paths necessary for transmitting the power through the circuit. A conductive connector was designed to provide a snap fit on the battery terminals while contacting the motor terminals at enough pressure to overcome the internal resistance and ensure current flow. The non-conductive holder which applies the required pressure to maintain the assembly in conductive contact was subjected to topology optimization, with future optimization strategies also discussed. The assembly was then manufactured and operational testing was performed, demonstrating a working product.