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Thermoplastic polyurethane (TPU) is a thermoplastic elastomer, which means it can be melted and reformed multiple times without losing its elastomeric properties. It offers excellent flexibility, elasticity, and resistance to abrasion and impact, making it suitable for producing parts such as gaskets, seals, phone cases, and shoe soles. TPU parts that are additively manufactured through fused deposition modeling (FDM) process have shown promising elastomeric properties compared to conventionally manufactured parts. TPU comes in various shore hardness ratings, allowing for customization of material stiffness. Common shore hardness ratings for TPU used in 3D printing range from 85 to 95 A. The present study focused on potential variations in tensile strength and elongation properties of TPU with respect to variation in the process parameters. It is generally known that, higher the elongation, lower the shore hardness rating. In the present study, significant FDM process parameters like printing speed, extruder temperature, and layer thickness were systematically varied while infill density was kept constant. The experiments were arrived out as per the design created with Response Surface Methodology (RSM) optimization technique. The obtained results from the experiments were given as response to the statistical software. Surface plots were generated to examine how process parameters interact with the response variable. Contour plots were generated to visualize the response variation with respect to the variation in the parameter levels. Tensile testing on the printed specimens was carried out as per the ISO 527-2 standard to evaluate the specimens. By optimizing various parameters, the investigation identified that the highest tensile strength (26 MPa) and elongation (352%) could be attained with a printing speed of 40 mm/s, a layer thickness of 0.26 mm, and an extruder temperature of 235 °C. The outcomes of this research have direct implications for industries requiring compliant and resilient gasket solutions, such as automotive, aerospace, and manufacturing where reliable sealing and resilience to environmental factors are critical.

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Process Parameters Optimization Through Response Surface Methodology for Enhanced Strength of Additively Manufactured Thermoplastic Polyurethane Parts

  • 会议论文

  • 发表日期：

    2025年

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  • P. Chandramohan,
  • M. S. Bala Santhosh,
  • R. Raghu

摘要

Thermoplastic polyurethane (TPU) is a thermoplastic elastomer, which means it can be melted and reformed multiple times without losing its elastomeric properties. It offers excellent flexibility, elasticity, and resistance to abrasion and impact, making it suitable for producing parts such as gaskets, seals, phone cases, and shoe soles. TPU parts that are additively manufactured through fused deposition modeling (FDM) process have shown promising elastomeric properties compared to conventionally manufactured parts. TPU comes in various shore hardness ratings, allowing for customization of material stiffness. Common shore hardness ratings for TPU used in 3D printing range from 85 to 95 A. The present study focused on potential variations in tensile strength and elongation properties of TPU with respect to variation in the process parameters. It is generally known that, higher the elongation, lower the shore hardness rating. In the present study, significant FDM process parameters like printing speed, extruder temperature, and layer thickness were systematically varied while infill density was kept constant. The experiments were arrived out as per the design created with Response Surface Methodology (RSM) optimization technique. The obtained results from the experiments were given as response to the statistical software. Surface plots were generated to examine how process parameters interact with the response variable. Contour plots were generated to visualize the response variation with respect to the variation in the parameter levels. Tensile testing on the printed specimens was carried out as per the ISO 527-2 standard to evaluate the specimens. By optimizing various parameters, the investigation identified that the highest tensile strength (26 MPa) and elongation (352%) could be attained with a printing speed of 40 mm/s, a layer thickness of 0.26 mm, and an extruder temperature of 235 °C. The outcomes of this research have direct implications for industries requiring compliant and resilient gasket solutions, such as automotive, aerospace, and manufacturing where reliable sealing and resilience to environmental factors are critical.