Mechanical Strength of Additive Manufactured and Standard Polymeric Components Joined Through Structural Adhesives

Area of Science:

• Materials Science
• Mechanical Engineering
• Additive Manufacturing

Background:

• Additive manufacturing (AM) allows complex geometries but is limited in build size.
• Extruded plastic parts offer structural integrity and cost-effectiveness.
• Hybrid assemblies combine AM's flexibility with traditional parts' strength.

Purpose of the Study:

• To evaluate the mechanical properties of hybrid assemblies joining AM polymer parts with standard plastic parts using structural adhesives.
• To assess the performance of rigid and toughened acrylic adhesives in these hybrid joints.
• To demonstrate the feasibility of using adhesives to create larger hybrid components.

Main Methods:

• Combined numerical and experimental analysis of pin-collar joints.
• Testing of realistic hybrid complex joints bonded with acrylic adhesives.
• Materials used: ABS (3D-printed), PVC (standard), rigid acrylic adhesive, toughened acrylic adhesive.

Main Results:

• Pin-collar joints showed adhesive failure with average shear stresses of 11.5 MPa (rigid) and 5.22 MPa (toughened).
• Stiffness values were 4449 N/mm (rigid) and 3649 N/mm (toughened) for pin-collar joints.
• Adhesive bonding successfully achieved the load-carrying capacity required for structural joints, matching traditionally manufactured parts.

Conclusions:

• Structural adhesives are a viable method for joining AM and standard plastic parts.
• This hybrid approach expands the size potential of 3D-printed components by integrating cost-effective extruded sections.
• The technique facilitates the creation of larger, high-performance hybrid parts using readily available materials.