Combination Bolt and Electrical Connector

grabcad

Not sure if this is acceptable for this challenge because it requires metal printing but please see the description below: I designed an integrated bolt and electrical connector that would require 3D printing to manufacture. The fastener/connector requires the use of three materials to build. It has steel for the bolt body, copper for the connector pins, and a type of insulating plastic (modeled with nylon) to separate the pins and bolt body. I believe this would be a great candidate for direct metal laser sintering (DMLS). This fastener design is designed to be used in experimental vacuum or pressure vessels that require minimal amounts of potential leakage areas. It integrates a structurally sound fastener, which would be used to clamp a lid or body members of the vessel together. It would also provide a path for electrical current to enter the vessel for monitoring equipment or electrical actuators. I believe the fastener would also provide value in the aerospace and automotive industries. It would allow for leaner design, similar to the way that automotive engines are used as structural members in some applications, this design would integrate electrical connectors into that category. The bolt is designed to have a larger structural body, which is similar to the common Hex Head Bolt. However, there are two reduced diameter members extending from the Hex Head and where the threaded portion of the bolt would normally start. These reduced diameters allow for smaller threaded sections where an electrical screw on connector can attach to and interface with the integrated electrical pins inside the bolt body. There are several isometric views of the fastener, with and without electrical connectors and simulated plates to visualize fastened bodies. The cross section shows the orientation of the three materials, essentially a standard electrical wire impregnated in a bolt. The bolt can be accompanied by standard washers, nuts and other hardware. Please feel free to leave questions in the comment section. -Thanks, Jeff