Motivation: To design and build a cantilevered structure that would be able to hold a load of at least 325 lbs, while being as light as possible.

This project was done as a team, where I worked on running the FEA analysis and also machining and assembling parts of the lightweight structure.

Analysis: 

Using CREO, we ran an FEA analysis on our CAD model, testing two different designs as well as Aluminum 6061 and Aluminum 7075. The results are shown below:

Additionally, buckling analysis (for the first 4 modes) was performed using a load of 425 lbs (safety factor = 1.3). The results are shown below:

Manufacturing: 

For easy of manufacturability, the circular design was chosen. Using a circle cutter, 6061 sheet Aluminum was cut into circles. Reinforcements using 7075 Aluminum were added. Eventually, the crane did lift 455 lbs and failed at 480 lbs. It, as predicted by the analysis, buckled at 485 lbs. The image of the broken lightweight structure is shown below.