tensile, compression, and torque force testing fixtures

Problem

The company’s products required fixtures to stabilize each component during force measurement tests.

Objective

To create/update fixtures (inherited an older design from a colleage) for various force testing for design verification testing, including: an off-axis tensile test, a button compression test, and a torque test.

Skills Employed

SOLIDWORKS 3D CAD model
3D printing - FDM and SLA
Machine shop manufacturing and tool use (tapping, drills, sanding)
Test method characterization and development
Testing fixture design/mechanical testing
Instron Tensile and Compression Testing

Figure 1. 3D CAD Model of compression testing fixture

Figure 2. 3D CAD Model of torque testing fixture

Approach

After being tasked with designing and prototyping fixtures, I developed a list of the design requirements and started to sketch some ideas of how these fixtures would operate and function. For the button compression and torque test fixtures, I started designing the fixtures in SOLIDWORKS. For the off-axis tensile test fixture, I made a few dimensional design changes to the SOLIDWORKS model and test printed a few prototypes using 3D printers. From there, I was able to test the fixture with a few sample parts and characterize the test methods.

After finalizing the designs, I ordered the necessary parts from McMaster-Carr. After a few trial test runs, the initial versions of the fixtures were developed and ready for testing.

Results

The fixtures successfully stabilized each product and allowed for consistent and accurate measurements. Additionally, a test method was drafted and developed for the new off-axis tensile test.