Analytical and Experimental Study of Light Weighted 3D printed Bolt using Stereolithography Process

Abstract

The growing demand for lightweight, high-performance components in fields such as aerospace, automotive, and biomedical engineering has led to increased research into innovative design and manufacturing methods. Among these, additive manufacturing (AM), particularly Stereolithography (SLA), has emerged as a promising technology due to its high precision, smooth surface finish, and ability to fabricate complex geometries with ease. This thesis presents an analytical and experimental investigation into the design, fabrication, and performance evaluation of light-weighted 3D printed bolts using the SLA process. The study primarily focuses on two aspects: weight optimization through structural modification of standard bolt geometry, and the mechanical performance of the printed components under compressive loading. Bolts are critical fastening components, traditionally manufactured using subtractive processes and metallic materials. However, in lightweight applications where mechanical loads are moderate and weight is a limiting factor, polymer-based, additively manufactured bolts present a novel alternative. This research aims to explore this potential by integrating design optimization and stereolithography-based fabrication, followed by experimental validation. Print settings such as layer thickness, exposure time, and orientation were carefully selected based on prior Taguchi and response surface methodology (RSM)-based optimization studies to ensure dimensional accuracy and strength. This thesis also discusses the limitations of SLA-printed polymer bolts, including their brittleness, limited thermal resistance, and unsuitability for high-load or fatigue-prone environments. However, it also highlights the potential advantages, such as weight savings, design flexibility, and the ability to create functionally integrated parts with embedded features. The present study demonstrates that SLA-based 3D printing is a viable method for producing lightweight bolts for specific engineering applications where moderate strength, low weight, and custom geometry are required. The outcomes of this research can guide future work in multi-material printing, composite resin development, and topology-optimized functional parts for structural and semi-structural applications.