Influence of Processing Conditions on Thermal Insulation Characteristics of 3D-Printed Thermoplastic Polyurethane

Fused filament fabrication (FFF) 3D printing technology has revolutionized the manufacturing industry with its design flexibility, economic effectiveness, minimal waste, and customization capabilities. 3D printing permits the development of insulating materials with customized design for various applications. The current study is focused towards the processing of the insulating materials and characterization using experimental and finite element analysis. In fused filament fabrication (FFF), process conditions play a major role in deciding the end product’s overall behaviour. Thermoplastic polyurethane is an ideal choice for automotive applications due to its low thermal conductivity, flexibility, durability, flexural strength, chemical, and abrasive resistance. To measure the thermal conductivity of the 3D-printed samples, thermal conductivity measurement setup that complies with ASTM C177/C1044 standards has been developed in-house. The thermal conductivity of the 3D-printed samples is also measured and reported. Steady-state heat conduction has been carried out using finite element method based commercially on available Abaqus software, and the effect of design pattern employed on the thermal conductivity is computed and reported. According to experimental and numerical findings, the thermal conductivity of the TPU is reduced for the given design pattern as compared to the solid TPU.