Animaris Geneticus Parvus Design of a complex multi-body walking mechanism

Purpose - This paper investigates how designers exploit the full potential of additive manufacturing ( AM). AM yields a broad range of advantageous properties including the possibility to fabricate mechanical multi-body structures. Design/methodology/approach - This case study explores the possibilities and limitations in designing mechanical multi-body structures for AM, focused on the development of a selective laser sintering ( SLS) version of Theo Jansen's Strandbeest walking mechanism, dubbed Animaris Geneticus Parvus ( AGP). We discuss the design process and considerations involved and attempt to distill design guidelines. Findings - Novel structural solutions were developed to enable SLS fabrication of the AGP, specifically cross-shaped pivot pins, increased clearance between bodies, spacing studs, restricting axial play with pins, partial disassemblies and increased clearance around extremities. The result is a functioning walking mechanism of 74 components can be fabricated at once without human intervention. Research limitations/implications - This article represents a case study; although it does mention adapted design rules for SLS, its greatest contribution is the holistic approach - to integrate a number of engineering challenges in one prototypical manifestation. Practical implications - Part consolidation by AM could bring great benefits in future product design applications. The findings show that complex multi-body mechanical structures with more than 70 elements are feasible by AM without assembly. This presents new business opportunities for AM service bureaus and novel product opportunities for designers. Originality/value - As a case study, this article provides inspiration of the mechanical complexity beyond regular products - from original idea to end result. For researchers, key contribution is the approach in obtaining design optimization strategies which provides engineering designers with a new language to consider SLS.