Exploring Parametric Screw Jack Design through 3D Printing

Abstract

A screw jack is a tool for lifting heavy loads with little effort. In this paper, the design, model and fabrication of a Screw jack using 3D Printing Technology is discussed. Digital fabrication, or 3D printing or additive manufacturing, creates physical objects from a geometrical representation by successive addition of materials. In agriculture, health care, motor vehicles, locomotives and aviation, 3D Printing is increasingly being applied for mass customization or production for all types of open-source design. Design is an important industrial activity which influences the quality of the product. The parts of a screw jack are modeled by using the modelling software Creo Parametric. The CAD model of the screw jack is then converted into. STL (Standard Tessellation Language) format in which the 3D Printer receives the printing input. The STL files are then imported to modelling software to analyze mesh and rectify errors. The rectified STL files of parts of the screw jack are imported to Makerbot software, and parts are made ready for 3D Printing using Makerbot FDM (Fused Deposition Modelling) 3D Printer. The parts printed in an FDM 3D printer are assembled based on the tolerances obtained, and the final prototype is fabricated.

Introduction

A screw jack is a mechanical device used to lift or lower heavy loads with minimal effort. It operates on the power screw principle, converting rotary motion into linear motion. Common types include mechanical and hydraulic jacks. Mechanical jacks are hand-operated or power-driven, while hydraulic jacks use a piston and cylinder mechanism. Screw jacks are widely used in automotive, industrial, and aircraft maintenance.

II. Components of a Screw Jack

• Screw & Nut: The nut is fixed in place while the screw rotates to raise/lower loads.

• Body: Usually a conical, hollow frame that supports the system and distributes load evenly.

• Screw Spindle: Designed with strong threads (square/trapezoidal) to withstand pressure. Some types self-lock.

• Thread Profile: Square threads offer high efficiency but weak root strength.

• Nut: Made of softer, cheaper material than the screw to reduce wear costs.

• Tommy Bar: Lever used to apply torque.

• Washer & Cup: Washer prevents surface damage; the cup holds the load.

III. Design Calculations

• Load Capacity: 600 kg

• Material Used: PLA (Polylactic Acid)

  • Compressive Strength: 17.93 MPa

  • Tensile Strength: 46.77 MPa

Key Design Highlights:

• Screw Spindle:

  • Core Diameter: 47 mm

  • Pitch: 3 mm

  • Torque Required: 40.3 Nm

  • Stress Checks (Compressive, Torsional): Within safe limits

  • No risk of buckling due to low slenderness ratio

• Nut Design:

  • Height: 24 mm

  • Bearing Pressure: 3.4 MPa

  • Dimensions adjusted to avoid crushing or tension failure

• Tommy Bar:

  • Length: 250 mm

  • Torque Application: 40.3 Nm

  • Diameter Calculated: 12.06 mm

IV. 3D Modeling

The screw jack was designed using Creo Parametric software, including detailed part modeling with standard engineering features.

V. Fabrication via 3D Printing

• Technique Used: Fused Deposition Modeling (FDM)

• Software Conversion: CAD model exported to STL format

• Printer Used: MakerBot Replicator Z18

• Printing Process: Model sliced into thin layers using “Slicer” software for additive manufacturing

VI. STL File Format

• Common file type for rapid prototyping

• Represents 3D models with triangulated surfaces

• Widely used for 3D printing across various platforms

Conclusion

3D Printed prototypes allow for better decisions. Before proceeding with full-scale production, designers and engineers can test, validate, and improve their ideas through the crucial prototyping stage in the product development process. Prototyping has experienced a revolutionary change since the development of 3D printing technology, offering many advantages that speed up the design iteration process and foster creativity. The three main elements of the testing phase of product development are functional testing, design verification, and assembly interconnection testing. Designers can imitate real-world settings and assess how well the design functions by creating functioning prototypes with qualities comparable to the final product. This allows designers to detect any defects or areas for improvement early in the development process. Design verification makes it possible to find and fix design flaws, evaluate proportions, and confirm that the specifications are met as planned. Functionality in many goods depends on component interconnection and correct assembly. Early detection of assembly difficulties or other problems allows designers to make the required corrections and guarantee smooth component integration. The screw jack\'s components are created, sculpted, and 3D printed using PLA (polylactic acid) material on a Fused Deposition Modelling Makerbot Replicator Z18 3D printer. The 3D-printed parts are then combined, and testing shows that the 3D-printed screw jack functions and has good dimensional accuracy. 3D printing prototyping has many advantages that transform the field of product creation. It permits customization and optimization while decreasing expenses, lowering risks, and speeding up design iterations. The goal of the 3D printed prototype is to provide a clear vision that includes the product\'s precise shape, user-centric design, enhanced communication, and later iterative development.

References

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Copyright

Copyright © 2025 B. Praneeth, A. Yashwanth Kumar , G. Pavan, K. Ramakrishna, M. Sai Kiran Naik . This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.