2023 ASEE Annual Conference & Exposition

Additive manufacturing (AM) is a relatively recent development in manufacturing which represents a paradigm shift in the way parts are made. Creating parts layer by layer offers many benefits including the ability to create parts with high level of geometric complexity, while forgoing the need for molds and dies, vertical integration of design and manufacturing activities, and the facilitation of customization even at mass. In the area of product development those benefits make design iterations fast and inexpensive, which not only translate into shorter development cycle, but also empower engineers to innovate in way not possible before. In a preceding work, we showed how interdisciplinary team of students developing a modular quadcopter drone ideated, built, and tested several innovative concepts, all of which were enabled by AM. In this work, we extend the preliminary work on the development of a concept for a customizable 3D printed power distribution board to replace a typical commercially available PDB which will further support additional innovations in modularity and improved functionality. The students designed the board, built it using FDM 3D printing, and tested it under maximum load conditions to ensure its proper functioning without excessive heating. Preliminary testing showed that, within the normal operating time before battery recharging becomes necessary, the board’s temperature increases by about 18 oF, which is acceptable. As a final step in the pursuit of this concept, the board was integrated into the drone body and a procedure for embedding the electric wiring was developed. This integration required several design modifications, which were implemented and prototyped. We believe that this modular drone development project design and mentorship guided by the principles of experiential learning and empowered by AM has increased the efficacy of students and helped them develop several skills that are valuable to the future engineering work force including team skills, leadership, time-management, life-long and interdisciplinary learning, and entrepreneurship mindset. Through a survey and focus group approach, the findings of an independent evaluator confirm those benefits to the students participating in the project.