Resin-Printed Jigs & Fixtures for EV-Battery Assembly

Description:

The team designs, prints, and validates production-adjacent jigs and fixtures with a Formlabs SLA printer to support EV-battery pack tasks such as pouch-cell alignment, tab protection during welding, busbar positioning, and quick inspection gauges. They begin by translating real workstation needs into functional requirements (tolerances, clamping force, ESD/safety, chemical exposure), then create CAD models optimized for SLA printing, including fillets, lattice/lightweighting, and insert seats for fasteners or magnets. They develop print strategies—orientation, supports, layer height, and resin choice—and document post-processing steps (wash, cure, dimensional stabilization) that most affect accuracy and durability. They benchmark dimensional accuracy (X/Y/Z bias, hole fit), surface finish, and mechanical performance across representative resins (e.g., tough/rigid/heat-resistant/ESD) and iterate with shrink/scale compensation to hit target fits (e.g., H7/h7-like clearances for press-fit pins). They evaluate fixture ergonomics and robustness through repeated cycles, measuring wear at contact points and tracking failure modes (cracking, creep, delamination) under plausible shop conditions. They compare cost and lead time versus CNC or FDM alternatives and produce a simple ROI calculator for lab use. They pilot the best designs on a mock EV-battery workstation to verify task time, error rate, and rework reduction, capturing video and metrology logs for evidence. They finalize a concise design guide with validated print profiles, tolerance tables, bill of materials, and safety/SOP notes so future student teams can replicate and extend the library of jigs and fixtures. 

Duration: Fall/Spring 

Team: 2 graduate students and 1 undergraduate student 

Compensation: Unpaid

Preferred Skill and Knowledge:

  • CAD (Fusion 360 or SOLIDWORKS) and STL export
  • PreForm slicing, SLA safety, and post-processing (IPA wash, UV cure)
  • Basic metrology (calipers, gauges) and simple mechanical testing with data logging (Excel/Python)
  • Working knowledge of Formlabs resins (tough/rigid/flexible trade-offs) 

Application Procedure:

Please send your resume and a short explanation of the project areas you're interested in and why to Chang S. "CS" Nam (csnam@ncat.edu).