Design and Materialization of Multi-Material Models for Fabrication via Fused Deposition Modelling

The objective of this thesis is to design and create a joystick, based on the force sensing units using multi-material Fused Deposition Modelling (FFF/FDM). The thesis covers the process and parameters involved in designing and producing a resistive force sensor, focusing on considerations for integrating flexible conductive TPU and PLA materials into a functional component. Data collection is carried out using a testing machine, and an analysis of the sensor's signal during loading and unloading cycles is performed to characterize its response. Additionally, the project encompasses design iterations, an economic assessment of the proposed solutions, and a sustainability analysis of the outcomes. In particular 3 designs have been advanced, considering for each time a weight and costs optimization: First Design (30g, 9,9 €), Second Design (27g, 8,91 €), Final Design (20g, 6,6 €). While the primary focus is on the manufacturing process, the thesis also addresses the feasibility of integrating the sensor into external systems. The research is driven by the need for mobility assistance devices for individuals with severe motor disabilities, specifically targeting wheelchairs.