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Catapult Design, Stress Analysis & Validation

Spring 2025

Overview

Premise

Design and manufacture a 3D-printed catapult, predict its performance and structural limits, and compare those calculations with physical testing.

What I Did

I worked on design calculations, CAD modeling, ANSYS stress analysis, prototype fabrication, projectile-launch testing, and progressive loading of the catapult arm until failure.

Results

The team developed and tested multiple designs, compared calculated and measured launch distances, and carried out destructive testing to investigate the failure predictions from ANSYS.

Spring 2025

Skills

  • CAD
  • Engineering Drawings
  • Strength of Materials
  • Dynamics
  • ANSYS FEA
  • PLA 3D Printing
  • Stress Analysis
  • Destructive Testing
  • Experimental Validation

My Role

  • Developed catapult designs and engineering calculations to estimate projectile range and structural loading.
  • Built 3D CAD models and drawings within the required dimensional and assembly constraints.
  • Examined 3D-printing parameters, including shell thickness, infill pattern, and material distribution, using 20% gyroid infill for fabrication.
  • Performed ANSYS FEA to estimate stress concentrations and likely failure locations.
  • Assembled and tested 3D-printed components, modifying the design through multiple iterations.
  • Compared measured launch distances with calculated predictions.
  • Gradually increased the applied load until the arm failed, recording failure behavior and comparing it with the simulation.

Accomplishments

  • Designed and evaluated multiple catapult iterations.
  • Applied ANSYS stress analysis before destructive testing.
  • Manufactured parts using 20% gyroid infill.
  • Tested both projectile-launch performance and mechanical failure under increasing load.

Pictures & Visuals

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