Structural Integrity of Polymeric Components Produced by Additive Manufacturing (AM)-Polymer Applications

Area of Science:

• Materials Science
• Mechanical Engineering
• Additive Manufacturing

Background:

• Additive Manufacturing (AM) using Fused Deposition Modelling (FDM) is increasingly explored for functional components.
• Traditional manufacturing limitations and costs drive the need for alternative production methods.
• Polylactic acid (PLA) and Nylon 645 are common polymers used in FDM.

Purpose of the Study:

• To evaluate the structural integrity and functional viability of FDM-produced components from PLA and Nylon 645.
• To quantify potential cost savings and mass reduction achievable through AM.
• To demonstrate the application of AM for end-use parts, overcoming prototyping limitations.

Main Methods:

• Redesign and Finite Element Method (FEM) analysis of a Polylactic acid (PLA) component from a brewing company.
• 3D printing of the redesigned PLA component using Fused Deposition Modelling (FDM).
• Additive manufacturing of a Nylon 645 airplane component (hanger) and comparison with the original metallic part.

Main Results:

• The 3D printed PLA component, despite lower durability, yielded annual savings of approximately EUR 7000.
• A Nylon 645 airplane hanger achieved a 60% mass reduction while maintaining functionality.
• FDM-produced components were successfully implemented as fully functional parts, not just prototypes.

Conclusions:

• Additive manufacturing with PLA and Nylon 645 via FDM is a cost-effective and efficient method for producing functional components.
• AM offers significant potential for cost reduction and weight optimization in various industries.
• The study validates the use of FDM for end-use applications, challenging previous perceptions of its limitations.