Design and fabrication of accelerometer sensor using fused filament fabrication technique

This research aims to investigate the design and manufacturing possibilities of micro-electro-mechanical devices, specifically accelerometers, utilizing a fused filament fabrication (FFF) system. This study involves the design of a 3D model for an accelerometer sensor, followed by the selection of suitable materials for its fabrication. Polylactic acid (PLA) is chosen for constructing the base structure, while conductive acrylonitrile–butadiene–styrene (ABS) is utilized for the sensing layer. Three distinct sensor models are generated, each featuring different shapes of sensing layers. Subsequently, various combinations of sensor models are subjected to testing using a source measurement unit to maintain constant voltage while measuring current, enabling the calculation of resistance values. The study reveals that both the selection of materials and the design of the sensing layer exert a substantial influence on sensor performance. Through the comparison of various sensor models and configurations, the research endeavors to pinpoint the most effective sensor design, characterized by commendable sensitivity and a streamlined manufacturing process. This study makes a significant contribution to the advancement of micro-electro-mechanical device fabrication through additive manufacturing (AM) or 3D printing by exploring the design and material selection for sensors. Present study offers valuable insights that could pave the way for the development of enhanced sensitivity in sensors with low cost and the optimization of manufacturing processes.