Simulation and Additive Manufacturing of a Crankshaft Component using Fused Deposition Modelling Techniques

Abstract

Additive Manufacturing (AM), commonly known as 3D printing, builds parts layer by layer directly from a 3D CAD model, which reduces material usage and gives designers greater flexibility than conventional methods. This study presents the design, simulation, and manufacture of an automotive crankshaft using Fused Deposition Modelling (FDM). The crankshaft was designed in SolidWorks and exported in STL format for manufacture in PLA. The analysis was performed under static loading conditions to assess stress distribution, deformation, and strain, along with fatigue life. The results showed that stress concentration was highest in the fillet region and that deformation was greatest in the crankpin neck region, although both remained within the yield criteria of the material. The printed prototype showed acceptable mechanical characteristics, good dimensional accuracy, and minimal material waste. Compared with conventional subtractive manufacturing, FDM reduced cost, tooling, and lead time while still allowing the part to be customised. These findings confirm that additive manufacturing is an effective method for the rapid prototyping of automotive components and can improve industrial productivity through more sustainable manufacturing. Future work should extend the analysis to a wider range of loading conditions and materials, and validate the simulated fatigue life through physical testing before the parts are used in service.