Cartesian Rotary 3D Braider

University of Alberta — Master’s Thesis Project

Problem

To consistently produce 3D braided structures, part of my thesis work involved designing a machine capable of creating 3D braids. The system used a computer as the central controller, with a microcontroller managing the stepper motors to achieve precise, repeatable motion. Producing 3D braided composites requires this level of control, yet commercial equipment is expensive, inflexible, and largely inaccessible—most 3D braiders are used only in military and aerospace applications. This custom system enabled research into braid geometry and mechanical properties that would otherwise be difficult to explore.

Approach

• Continued and expanded on prior research by designing and building a custom 3D braiding machine capable of producing consistent braided structures.

• Integrated a computer-based control system as the central “brain,” paired with a microcontroller-driven stepper motor system for precise control of yarn carriers.

• Developed custom software in MatLab and C/C++ to control machine operations, visualize braid geometry, and predict material properties.

• Automated CAD generation of braid structures for subsequent finite element analysis (FEA) and mechanical testing.

Result

Delivered a working 3D braiding machine that provided reliable production of braided composites, enabling advanced testing and modeling. The system gave researchers the ability to link braid architecture to mechanical performance, forming the foundation of your graduate thesis work.

To be able to consistently and reliably produce 3D braided structures, part of my thesis work was to continue the work of a previous student and design a machine capable of producing 3D braids. This machine utilized a computer as the brain of the system, and a micro-controller as the stepper controller. 

Thesis

Presentation