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Wear Behavior and Multi-Technique Characterization of 3D Printed TPU Under Simulated Pharmaceutical Operating

Maria Stoica¹, Marius Gabriel Petrescu¹, Maria Tănase¹

¹Mechanical Engineering Department, Petroleum-Gas University of Ploiești, 100680 Ploiesti, Romania.

|March 14, 2026

Summary

Optimizing 3D printed thermoplastic polyurethane (TPU) for friction layers involves balancing wear resistance and mechanical properties. The best performance was achieved with TPU 51A printed at higher temperatures and layer counts, showing reduced wear.

Keywords:

DSC FDM FTIR SEM TGA XRD hardness pharmaceutical tensile test wear

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Area of Science:

Materials Science
Tribology
Additive Manufacturing

Background:

Thermoplastic polyurethane (TPU) is crucial for friction layers in pharmaceutical manipulator transmission belts.
Understanding the impact of 3D printing parameters on TPU wear behavior is essential for optimizing performance.

Purpose of the Study:

To investigate the wear behavior and multi-technique characterization of 3D printed TPU (51A and 60A grades).
To evaluate the influence of printing temperature and layer count on mechanical and tribological properties.
To determine the optimal printing conditions for TPU friction layers.

Main Methods:

Fused Deposition Modeling (FDM) used to print TPU specimens with varied temperatures and layer counts.
Characterization included Shore A hardness, wear resistance (Baroid lubricity tester), tensile properties, XRD, FTIR, TGA, and SEM.
Analysis focused on the relationship between printing parameters and material properties.

Main Results:

Printing parameters significantly affect TPU mechanical and tribological behavior.
TPU 51A printed at 265 °C with four layers showed reduced wear but lower hardness.
TPU 60A exhibited increased hardness and wear with higher printing temperatures and layer counts.
Interlayer bonding improved with fewer layers, enhancing tensile properties.
Wear resistance is influenced by hardness, cohesion, and microstructure, not solely crystallinity.

Conclusions:

3D printed TPU properties are highly dependent on processing parameters.
TPU 51A printed at 265 °C with four layers offers a promising balance for friction layer applications.
Further optimization of FDM parameters can enhance the suitability of TPU for demanding applications.