Session: 03-08-03: Computational Modeling and Simulation for Advanced Manufacturing

Paper Number: 145834

145834 - Enhancing Mechanical Properties of 3d Printed Polymers Through Metallic Surface Coating: A Finite Element Analysis 

Additive Manufacturing (AM) has made it possible to manufacture intricate designs, like lattices, with geometric accuracy, reduced material wastage, and enhanced mechanical properties. Advancements in AM have made polymer 3D printing cost-effective, time-efficient, and require minimal post-processing. However, 3D printing of metallic parts presents challenges, has limitations, and is expensive. We could leverage the advantages of AM by coating 3D-printed polymers with metals. It could improve thermal properties, conductivity, wear resistivity, and aesthetical appearance and may lead to higher strength-to-weight ratios.

This study reports the finite element modeling and linear (elastic) analysis of the strut-based lattice structure with metal surface coating under uniaxial load. According to the standard test method for Tensile Properties of Plastics D638-22, the ASTM Type III dog-bone specimen was modeled with a gauge length of 50 mm and thickness of 9.5 mm. Diamond-type face-centered strut-based lattices were created in the narrow section of the specimen. To replicate metal coating, the surface body is created on top of the outer surface of the test specimen with conformal mesh.

The factors that were varied in this study were the base material, the coating material, and the coating thickness. ABS (Acrylonitrile butadiene styrene) and vat photopolymerized resin were considered for the main body (base material) of the model. At the same time, common metals Copper (Cu) and Nickel (Ni) were utilized as coating materials. Coating thickness was varied from 10 μm to 500 μm, and incremental load was applied until the model exhibited elastic yielding. For coating metals and ABS, maximum equivalent stress (von-mises stress) based yielding was considered, whereas, for the vat photopolymerized grey resin, which is brittle, maximum principal stress was considered.

The study revealed that the equivalent modulus of elasticity of the specimen was improved with the application of metal coating. The modulus was observed to be maximum (nearly increasing by a factor of 40) when the coating thickness was minimum and gradually decreased as the coating thickness increased. Mechanical properties like the resilience and strength of the model increased with higher coating thickness. For all trails, maximum equivalent stress was obtained in coating, whereas the maximum total strain value was obtained in 3D printed material (Main Body). It was found that, except for 500 μm nickel coatings, coating material yields before the main body.

This investigation provides valuable insights into the structural performance enhancement of strut-based lattices through surface coatings, contributing to advancements in lightweight and efficient engineering materials and designs.

Presenting Author: Bibek Kafle Grand Valley State University

Presenting Author Biography: Bibek is a Graduate Student in the School of Engineering at Grand Valley State University.

Authors:

Bibek Kafle Grand Valley State University
Abishek Balsamy Kamaraj Grand Valley State University