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Modeling Materials Coextrusion in Polymers Additive Manufacturing.

Riccardo Sponchiado1, Stefano Rosso1, Pierandrea Dal Fabbro1

  • 1Department of Civil, Environmental, and Architectural Engineering, University of Padova, 35122 Padua, Italy.

Materials (Basel, Switzerland)
|January 21, 2023
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Summary

Material coextrusion in additive manufacturing allows for new material combinations. This study models and experimentally verifies the mechanical properties of Polylactic Acid-Thermoplastic Polyurethane and Acrylonitrile Styrene Acrylate-Thermoplastic Polyurethane blends.

Keywords:
additive manufacturingcoextrusionfused deposition modelingmaterial extrusionmaterial modeling

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Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Mechanical Engineering

Background:

  • Material extrusion additive manufacturing allows for combining multiple materials within a single nozzle.
  • Material coextrusion expands the range of achievable material properties and enables gradual property changes.
  • Understanding the mechanical behavior of coextruded materials based on their fractions is crucial for exploiting this technology.

Purpose of the Study:

  • To investigate the mechanical properties of Polylactic Acid (PLA)-Thermoplastic Polyurethane (TPU) and Acrylonitrile Styrene Acrylate (ASA)-TPU blends produced by material coextrusion.
  • To propose and validate an original model for material distribution in coextrusion.
  • To analyze the mechanical properties using analytical and numerical approaches and experimental verification.

Main Methods:

  • Developed an original model for material distribution in coextrusion.
  • Employed analytical modeling (set of rods assumption) and numerical modeling (homogenization theory, finite element analysis).
  • Conducted experimental tensile tests to validate the models and determine material properties.

Main Results:

  • Both analytical and numerical models showed similar trends, with the finite element model exhibiting more realistic behavior.
  • Experimental tensile tests yielded Young's moduli of 3425 MPa (PLA), 1812 MPa (ASA), and 162 MPa (TPU).
  • Intermediate material fractions showed an almost linear trend in Young's modulus and lower ultimate tensile strength values compared to neat materials.

Conclusions:

  • The developed models show good agreement with experimental results, providing valuable tools for designers.
  • This research contributes to the advancement of material coextrusion in additive manufacturing.
  • The study demonstrates the potential for tailored material properties through controlled coextrusion of compatible polymers.