Animaris Geneticus Parvus

Abstract

Purpose – This paper investigates how designers exploit the full potential of additive manufacturing (AM). AM yields a broad range of advantageous properties including the possibility to fabricate mechanical multi-body structures. Design/methodology/approach – This case study explores the possibilities and limitations in designing mechanical multi-body structures for AM, focused on the development of a selective laser sintering (SLS) version of Theo Jansen’s “Strandbeest” walking mechanism, dubbed Animaris Geneticus Parvus (AGP). We discuss the design process and considerations involved and attempt to distill design guidelines. Findings – Novel structural solutions were developed to enable SLS fabrication of the AGP, specifically cross-shaped pivot pins, increased clearance between bodies, spacing studs, restricting axial play with pins, partial disassemblies and increased clearance around extremities. The result is a functioning walking mechanism of 74 components can be fabricated at once without human intervention. Research limitations/implications – This article represents a case study; although it does mention adapted design rules for SLS, its greatest contribution is the holistic approach – to integrate a number of engineering challenges in one prototypical manifestation. Practical implications – Part consolidation by AM could bring great benefits in future product design applications. The findings show that complex multi-body mechanical structures with more than 70 elements are feasible by AM without assembly. This presents new business opportunities for AM service bureaus and novel product opportunities for designers. Originality/value – As a case study, this article provides inspiration of the mechanical complexity beyond regular products – from original idea to end result. For researchers, key contribution is the approach in obtaining design optimization strategies which provides engineering designers with a new language to consider SLS.