# Design and Contact Performance Analysis of 3D-Printed Alloy Metal Inertial Micro Switch

## TL;DR

This paper proposes a 3D-printed alloy metal inertial micro switch design that improves reliability and reduces space.

## Contribution

The novelty lies in using 3D printing to create an integrated inertial micro switch with verified performance under high acceleration.

## Key findings

- Aluminum alloy electrodes deform plastically and achieve stable contact within 5 µs under 627 N impact.
- Titanium alloy electrodes deform later than aluminum alloy electrodes under the same impact conditions.
- 3D printing is feasible for manufacturing high-precision, complex-structure micro switches.

## Abstract

In order to reduce space occupation and improve reliability, the modularization and integration of micro switches and their components are a necessary path for development. In this paper, a scheme for an alloy metal inertial micro switch using 3D printing technology is proposed for an integrated design. The switch realizes the turn-on function by causing the deformable electrodes to undergo plastic deformation and make close contact with the outer sleeve under the columnar block extrusion. The influence of electrode structure parameters on electrode contact performance was studied by the orthogonal experimental method. And the best parameter combination scheme for the electrode was determined. The aluminum alloy switch and titanium alloy switch were processed by SLM (selective laser melting) technology. The plastic deformation of the 3D-printed titanium alloy electrode occurred later than that of the 3D-printed aluminum alloy electrode under the same impact. The aluminum alloy electrode underwent plastic deformation and realized stable contact with a response time of 5 µs when the impact load was applied with an amplitude of 627 N and a pulse width of 2.7 ms (simulating high acceleration), which meets the application requirement of the response time being no more than 20 µs. The feasibility of 3D printing technology in high-precision and complex-structure micro switch manufacturing was verified. The research in this paper will provide guidance and reference for engineering applications.