In 2018, I had the privilege of spending the summer at Northwestern University’s MRSEC (Materials Research Science and Engineering Center). During this time, my focus was on characterizing fracture toughness in epoxy polymers at cryogenic temperatures, specifically for aerospace applications, involving a major space launch service provider.

One significant challenge I faced was using a dynamic mechanical analyzer to determine the maximum stress epoxy samples could endure before failure. Unfortunately, the samples frequently failed during the cooling phase when gaseous LN2 was introduced into the sample chamber. This was exacerbated by the thinness of the samples, the rapid gas influx, and the shrinkage of the 3-point bending apparatus, which continually compromised the experiments by causing sample instability.

Fortunately, Northwestern’s engineering center offered access to Stratasys FDM 3D printers. After careful consideration, I devised a solution—a U-shaped saddle that could be integrated into the 3-point bending tools to securely hold the samples upright without affecting the experimental integrity. Although seemingly simple, this innovation was a critical and non-trivial resolution to an ongoing experimental challenge.