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<p>Photoelasticity is a reliable experimental technique for analysing stress distribution in machine components with complex geometries. Conventional model preparation using metal moulds is often labour intensive and suffers from limitations related to surface finish, dimensional accuracy and replicability. Although additive manufacturing has improved fabrication flexibility, issues such as residual stresses, anisotropy and optical scattering persist. This study presents a comparative evaluation of three model-making techniques: wooden moulds, 3D-printed moulds and silicone rubber moulds used for photoelastic analysis. A hybrid approach combining additive manufacturing for pattern generation with conventional epoxy casting is explored to improve model quality while reducing fabrication complexity. The performance of each method is assessed through qualitative photoelastic observations under identical experimental conditions, focusing on transparency, dimensional fidelity, leakage behaviour, ease of demoulding and residual stress patterns. The results indicate that silicone rubber moulds prepared using 3D-printed patterns provide superior transparency, minimal residual stresses, and improved repeatability, making them well suited for accurate and reliable photoelastic experiments.</p>

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Hybrid Method for Model Making Using Silicone Rubber Mould and Additive Manufacturing Technique for Photoelastic Analysis

  • 期刊论文

  • 发表日期：

    2026年7月1日

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  • R. Chugh,
  • S. Nagpal,
  • S. Sanyal

摘要

Photoelasticity is a reliable experimental technique for analysing stress distribution in machine components with complex geometries. Conventional model preparation using metal moulds is often labour intensive and suffers from limitations related to surface finish, dimensional accuracy and replicability. Although additive manufacturing has improved fabrication flexibility, issues such as residual stresses, anisotropy and optical scattering persist. This study presents a comparative evaluation of three model-making techniques: wooden moulds, 3D-printed moulds and silicone rubber moulds used for photoelastic analysis. A hybrid approach combining additive manufacturing for pattern generation with conventional epoxy casting is explored to improve model quality while reducing fabrication complexity. The performance of each method is assessed through qualitative photoelastic observations under identical experimental conditions, focusing on transparency, dimensional fidelity, leakage behaviour, ease of demoulding and residual stress patterns. The results indicate that silicone rubber moulds prepared using 3D-printed patterns provide superior transparency, minimal residual stresses, and improved repeatability, making them well suited for accurate and reliable photoelastic experiments.