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Lightweight Ladder Support Bracket


Lightweight ladder support bracket designed to meet a defined load requirement while minimizing material. The part was modeled in CAD, evaluated under a distributed load in simulation, and refined to improve strength-to-weight performance. Final design was fabricated and validated in real-world use.



[HERO PICTURE]

 

The Problem/Requirement

  • 24 ft Fiberglass Extension Ladder
  • 50 lb total weight
  • Goal: Design most lightweight support bracket that can withstand the load with a sufficient safety factor. The bracket should also be capable of withstanding mild impact if ladder is lightly dropped onto bracket.

Initial Design

  • For the process, I chose to use SLA resin printing due to its isotropic mechanical properties.

  • For the material, I chose to use Formlabs Tough 2000 resin, which offers good stiffness and impact resistance.

  • Other key design criteria/choices

    • Fasteners: #9x3 in Deck Screws

      • .200 in major diameter

      • .350 in head diameter

      • 82 deg countersink angle

    • Material thickness = .125 in

  • This design was load tested and verified to be well beyond the desired factor of safety, making it suitable for further weight reduction.

  • To verify the load simulation and general fit/function, a prototype was printed out of PLA Tough+. Upon installation, it was determined the part could be smaller too.

Revised Design

  • After the initial design was validated, the following improvements were made.

    • The overall size was reduced by over 40%.
    • The solid rib was replaced with a truss design, reducing the volume by ~15%
    • Excess material between the mounting holes was removed. This had minimal impact on the overall performance of the part in the designed use-case, and reduced the volume by ~10%.
    • A lip was added to the end of the bracket to prevent the ladder from sliding off.

Final Validation

  • After the design was revised, it was validated with the following load case.

    • Applied distributed load: 50 lb

      • Chosen to simulate one bracket supporting the entire weight of the ladder
    • Constraints: Main load bearing on screw countersinks, secondary constraint from wall
  • Results: Minimum safety factor of 3.237
  • The final design was printed out of PLA Tough+ for a final prototype.

Production

  • After all validation efforts were completed, the part was printed out of the chosen Tough 2000 resin.
  • Printing the part was simple because it was designed specifically with printing in mind. Due to the efficient design, post-processing was simple.
  • The parts were then washed and cured per Formlabs's specifications to ensure designed mechanical properties.
  • The parts were then coated with a UV-resistant coating to prolong the lifespan.
 

Results/Conclusion

After final production, the parts were installed and tested. They meet the requirements of the project well and make ladder storage easier. The parts have been in-use with no issues since installation.

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