RESEARCH PAPER
3D Printing Technology as the Manufacturing Method of Complex Exoskeleton Elements Carrying Heavy Loads
 
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1
Department of Mechanics and Machine Design Fundamentals, Czestochowa University of Technology, Poland
 
2
Institute of Mathematics, Faculty of Control, Robotics and Electrical Engineering, Poznan University of Technology, Poland
 
 
Submission date: 2026-07-13
 
 
Final revision date: 2026-08-03
 
 
Acceptance date: 2026-08-04
 
 
Publication date: 2026-09-25
 
 
Corresponding author
Marcin Sebastian KUBIAK   

Department of Mechanics and Machine Design Fundamentals, Czestochowa University of Technology, Dąbrowskiego, 42-200, Częstochowa, Poland
 
 
Acta Mechanica et Automatica 2026;20(3):783-792
 
HIGHLIGHTS
  • designing high-load components manufactured using 3D printing
  • orthotropic material models for FEM analysis of selected exoskeleton joint components
  • 3D prints depend on material preparation conditions and loading direction
KEYWORDS
TOPICS
ABSTRACT
This article describes one of the challenges encountered when designing high-load components manufactured using 3D printing technology: ma-terial anisotropy. Using a lower-limb exoskeleton as a reference, the advantages and limitations of 3D printing were compared with those of con-ventional machining of metal components. The tensile strength was examined for PA6-CF specimens printed in the longitudinal and transverse directions, both before and after annealing. The experimentally determined orthotropic material properties were incor-porated into finite element models of the exoskeleton joint to evaluate the influence of material anisotropy on structural safety under nominal and peak loading conditions. The simulations demonstrated that the printed components remain safe under the rated motor torque, whereas higher overloads primarily threaten the interlayer (Z-direction) strength and require design or control-system limitations. The results indicate that print orientation and annealing affect the load-bearing capacity of the printed components, while the Z direction remains the most critical due to inter-layer bonding.
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eISSN:2300-5319
ISSN:1898-4088
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