Extrusion-Based Additive Manufacturing-Driven Design and Testing of the Snapping Interlocking Metasurface Mechanism ShroomLock

This study presents the manufacturing process-driven development of an interlocking metasurface; (ILM) mechanism for fused filament fabrication; (FFF) with a focus on open-source accessibility. The presented ILM is designed to enable strong contact between two planar surfaces. The mechanism consists of spring elements and locking pins which snap together when forced into contact. The mechanism is designed to deliver optimized mechanical properties, functionality, and printability with common FFF printers. The mechanism is printed from a thermoplastic polyurethane; (TPU) filament which was selected for its flexibility, which is necessary for the proper functioning of the spring elements. To characterize the designed mechanism, a tensile test is carried out to assess the holding force of the ILM. The force-displacement profiles are analyzed and categorized into distinct phases, highlighting the interplay between spring deformation, sliding, and disengagement. Finally, from the measurements of multiple printed specimens, a representative holding force is determined through averaging and assigned to the mechanism. The resulting tolerance, which can be attributed to geometric and material-related factors, is discussed. The testing results are discussed and compared with a numerical simulation carried out with a frictionless approach with a nonlinear Neo-Hookean material law. The study underscores the importance of meticulous parameter control in three-dimensional (3D) printing for the consistent and reliable performance of interlocking metasurface mechanisms. The investigation leads to a scalable model of an ILM element pair with distinct three-phase snapping characteristics ensuring reliable holding capabilities.