FEMS EUROMAT 2023
Lecture
06.09.2023 (CEST)
Influence of the Design of Architected Cellular Structures on the Mechanical Properties in Laser-based Powder Bed Fusion of Thermoplastic Polyurethane
JH

Joseph Hofmann (M.Sc.)

Technische Universität München

Hofmann, J. (Speaker)¹; Koller, N.¹; Bucht, L.²; Wudy, K.¹
¹Professorship of Laser‑based Additive Manufacturing, Department of Mechanical Engineering, TUM School of Engineering & Design, Technical University of Munich, Boltzmannstrasse 15, 85748 Garching; ²SQlab GmbH, Postweg 4, 82024 Taufkirchen
Vorschau
Untertitel (CC)

Applications, such as bike saddles, shoe soles, and car seats, typically rely on non-recyclable foam materials to absorb and dissipate vibration and shock while simultaneously providing cushioning and comfort to the user. Laser-based powder bed fusion of plastics (PBF‑LB/P) represents an innovative technology that fabricates fusible materials into architected cellular structures. This enables the production of sustainable products with customizable mechanical properties and dynamic material behavior. In PBF-LB/P, the melting of particles is determined by the maximum melt pool temperature and the polymer melt's cooldown behavior after laser exposure. Increasing maximum melt pool temperatures with increasing total laser energy input correlate with an increasing melt pool size at higher energy input. This, in turn, improves the load-bearing capabilities of thin structures. However, even at constant energy input, the melt pool temperature of individual layers varies depending on the exposed cross-section and the height of the underlying melt pool. As a result, the porosity, and the mechanical properties of filigree PBF-LB/P structures (< 2 mm) are strongly influenced by changes in geometric design and part orientation in the build volume. In the state of the art, the effect of these dependencies on the properties of the unit cell struts has not been well studied for thermoplastic polyurethane (TPU), which is commonly used to create components with elastic properties by tailoring architected cellular structures. In addition, the open-cell design of these structures leads to local pressure peaks that reduce user comfort. Therefore, the process of designing PBF LB/P components with architected cellular structures still follows a trial-and-error approach. Within the scope of this work, the influence of the unit cell design, i.e., the cell type, cell size, and strut diameter, on the compression and damping properties and the user comfort of TPU architected cellular structures is investigated. The architected cellular structure's compressive modulus, indentation hardness, compression set, and hysteresis loss rate increase when smaller cell sizes or larger strut diameters are used. Changes in the unit cell type (face-centered cubic and kelvin cell lattices) show marginal effects on the mechanical properties. The implementation of a shell layer in combination with smaller cell sizes and larger strut diameters homogenizes the local pressure distribution. This reduces the skin irritation of users in applications, such as cycling. The results are used to design a topology-optimized bike saddle that is tailored to specific load cases.

Abstract

Abstract

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