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<p>This study presents and evaluates an innovative snap-fit fastening screw assembly for high pull-out resistance, manufactured via additive manufacturing. The design utilizes Polylactic Acid (PLA) and features a dual-cantilever snap-fit mechanism reinforced by a locking pin support. Geometric optimization was conducted using the Taguchi method to achieve a “nominal-the-best” target pull-out force of 100 kgf, investigating four key factors: pin configuration, lower contact surface thickness, lower contact surface width, and chamfer size. The optimization results identified the optimal parameter combination as a rectangular pin with a thickness of 3.4&#xa0;mm, a width of 12&#xa0;mm, and a 1&#xa0;mm chamfer, yielding a predicted pull-out force of 99.6 kgf. Experimental verification yielded a pull-out force of 103.16 kgf, in close alignment with the design objective. Furthermore, validation via finite element analysis (FEA) revealed stress distribution patterns consistent with experimental observations. These findings confirm the accuracy and industrial reliability of the proposed optimization framework for high-strength additive manufacturing applications.</p>

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Design and optimization of a pin-reinforced snap-fit fastener via additive manufacturing for high-load sanitary applications

  • 期刊论文

  • 发表日期：

    2026年7月14日

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  • Fang-Sung Cheng,
  • Hong-Yi Zhan,
  • Chun-Ming Lin

摘要

This study presents and evaluates an innovative snap-fit fastening screw assembly for high pull-out resistance, manufactured via additive manufacturing. The design utilizes Polylactic Acid (PLA) and features a dual-cantilever snap-fit mechanism reinforced by a locking pin support. Geometric optimization was conducted using the Taguchi method to achieve a “nominal-the-best” target pull-out force of 100 kgf, investigating four key factors: pin configuration, lower contact surface thickness, lower contact surface width, and chamfer size. The optimization results identified the optimal parameter combination as a rectangular pin with a thickness of 3.4 mm, a width of 12 mm, and a 1 mm chamfer, yielding a predicted pull-out force of 99.6 kgf. Experimental verification yielded a pull-out force of 103.16 kgf, in close alignment with the design objective. Furthermore, validation via finite element analysis (FEA) revealed stress distribution patterns consistent with experimental observations. These findings confirm the accuracy and industrial reliability of the proposed optimization framework for high-strength additive manufacturing applications.