While many 3D printed structures are rigid and stationary, the potential for complex geometries offers a chance for creative and useful motion. Printing structures larger than the print bed, reducing the need for support materials, maintaining multiple states without actuation, and mimicking origami folding are some of the opportunities offered by 3D printed hinges. Current efforts frequently employ advanced materials and equipment that are not available to all users. The purpose of this project was to develop a parametric, print-in-place, self-locking hinge that could be printed using very basic materials and equipment. Six main designs were developed, printed, and tested for their strength in maintaining a locked position. Two general design types were used: 1) sliding hinges and 2) removable pin hinges. The test results were analyzed to identify and explain the causes of observed trends. The amount of interference between the pin vertex and knuckle hole edge was identified as the main factor in hinge strength. After initial testing, the designs were modified and applied to several structures, with successful results for a collapsible hexagon and a folding table. While the initial goal was to have one CAD model as a final product, the need to evaluate tradeoffs depending on the exact application made this impossible. Instead, a set of design guidelines was created to help users make strategic decisions and create their own design. Future work could explore additional scaling effects, printing factors, or other design types.

The majority of drones are extremely simple, their functions include flight and sometimes recording video and audio. While drone technology has continued to improve these functions, particularly flight, additional functions have not been added to mainstream drones. Although these basic functions serve as a good framework for drone designs, it is now time to extend off from this framework. With this Honors Thesis project, we introduce a new function intended to eventually become common to drones. This feature is a grasping mechanism that is capable of perching on branches and carrying loads within the weight limit. This concept stems from the natural behavior of many kinds of insects. It paves the way for drones to further imitate the natural design of flying creatures. Additionally, it serves to advocate for dynamic drone frames, or morphing drone frames, to become more common practice in drone designs.