I've started with a simple design for a headphone stand

I was a little worried that adding a load would cause this model fail to, so I ran a static simulation.

Although the results did not warn of a possible failure, but I used this as a basis to carry out a redesign optimizing the model, the stresses were at the highest point at 2.8 MPa and the displacements at 1.76 mm in the furthest area.

Although the results did not warn of a possible failure, I took this as a basis to carry out a redesign optimizing the model, the stresses were at the highest point at 2.8 MPa and the displacements at 1.76 mm in the furthest area. As with everything, at the moment I was considering a model for 3D printing with PLA material. I added a rib with enough angle to be able to start printing without needing supports, which added excess material to the model, but the stress and displacement results were reduced considerably, the stress from 2.8 Mpa to 1.8 Mpa and the displacement of 1.76. mm only .49mm, which gave me room where I could improve.

Then I created a 3rd model, this would work as a raw model of the previous support to have two starting points, one without support and a fully supported model and subsequently perform a topological analysis.

It was possible to lower the displacement to only 0.11 mm but the mass increased from 30.7 grams to 48.7 grams, so it was only a matter of configuring the topological study adding that the stress value did not exceed 1.8 MPa and in the condition of reducing the mass by below 33 grams.

The result is the following:

With this in mind I get to work to generate the following design

Which, if we remember that the reason was to do it in 3D printing, in PLA the 5° inclination angle meant that it was necessary to add supports in those areas, it sounds greedy but I will use those grams for other future projects.

Return to SolidWorks and change the 5° inclination to 0°, running the simulation again to identify the changes if they have greatly affected, all the redesigns were graphed with the “Trend Tracker” tool, which gave me the following results:

Changing to 0° allows me to keep the mass, tensions and displacements the same and also allowed me to now print without the need for supports.

Add some additional operations for a "press" type function with the thread commands.

The model already looked good so I sent it to my 3D printer without adding supports and in just 3 hours I had both pieces.

Final results

It will sound like a lot of time invested but the designs alone took me about 1:30 hours and the topological analysis was running while it was my lunch break, I think I have invested a little more time sharing this with you.

Although it was only a test that I was doing, I enjoyed being able to share this little project with you.