Abstract:
Additive manufacturing (AM) enables the production of complex geometries that are challenging
to achieve with traditional manufacturing methods. Wave springs, developed using AM, offer
superior load-bearing capacity, lightweight structure, high energy absorption efficiency, and
enhanced stiffness compared to conventional helical springs, making them ideal for advanced
engineering applications. This research examines the dynamic behavior of AM-fabricated wave
springs, with a focus on their potential for vibration isolation and energy absorption. Employing a
combination of finite element analysis (FEA) and experimental testing, the study evaluates the
effects of geometric variations on the damping characteristics and natural frequencies of the wave
springs. The findings reveal how AM enables the creation of wave springs with customized
dynamic properties, offering advantages in optimizing performance for specific applications and
functional requirements. The results indicate that the rectangular wave spring design exhibited a
damping ratio approximately 38% higher than the round design and 12% greater than the variable
thickness design. Additionally, the study examines the fatigue resistance of AM-fabricated wave
springs for all designs, assessing their durability under repeated loading conditions. It further
revealed a trade-off between resonance frequency and durability, with the rectangular design
achieving the highest fatigue life. By demonstrating the potential of AM to produce wave springs
with tailored dynamic properties, this research contributes to sustainable industrial innovation.
