Session: 03-09-03: Design of Engineering Materials

Paper Number: 88301

88301 - Characterization of Additively Manufactured Beta Materials 

Additive manufacturing (AM) is transforming industrial production. AM can produce parts with complex geometries and functionality. However, one of the biggest challenges in the AM world is limited material options. The purpose of this research is to develop new material mixtures and determine their mechanical properties for use at the MSOE Rapid Prototyping Center and provide valuable insight into beta materials for use in AM industry.  Elastomeric polyurethane (EPU 40) and Rigid polyurethane (RPU 70), resins developed by Carbon3D, are employed for this research. Initially, EPU 40 (100%) and RPU 70 (100%) were used to print tensile and hardness test specimens so that their mechanical properties could be compared to the standard values presented by Carbon and used as benchmarks for newly developed material. Mixtures of the two materials, EPU 40 and RPU 70, in multiple ratios were then created and used to print tensile and hardness test specimens. Data collected from tensile and hardness tests show that EPU 40 and RPU 70 can be combined in various ratios to obtain material properties that lie between the two individual components. In addition to developing these new materials, the effect of printing orientation on mechanical properties was also studied in this paper.

               Using a test specimen designed at MSOE RPC several combinations of EPU 40 and RPU 70  (100/0, 80/20, 60/40, 40/60, 20/80 and 0/100) were produced and tensile tests and durometer tests (Shore A and Shore D) were conducted. The results showed increase in tensile strength as RPU 70 percentage increased and so did the hardness. The hardness of EPU 40 (100%) and RPU 70 (100%) are pretty close to the data found in the technical data sheet, and all the values obtained for other combinations are in a reasonable range. While the trends were established using in-house test specimen design, the EPU 40 (100%) specimen was printed per the ASTM D412 die C and the RPU 70 (100%) was printed per the ASTM D638 type V which are the prescribed standards respectively. The properties were on par with the expected values. Concurrently, by blending in 50% each of EPU 40 and RPU 70, the tensile test specimen was 3D printed in both ASTM standards. Then, the tensile tests of these materials were conducted. For this research, the hardness of the samples was measured by employing a durometer (Shore A and Shore D scales).  The Shore A scale is used for softer rubber-like material, and the Shore D scale is used for harder material. In a 50/50 combination, both scales were used to ensure the results are meaningful. All copies of the test specimens were printed in the x-y (flat) and z (vertical) orientation to determine effect of orientation on the mechanical properties. In general, vertically printed specimens showed better mechanical properties compared to horizontally printed ones. The results will be shared in the paper which will be presented at the IMECE. The authors deduce that the idea of blending/combining two materials could be implemented in other materials to increase the option of 3D printing materials.

Presenting Author: Efrem Dana Milwaukee School of Engineering

Presenting Author Biography: Efrem is an undergraduate student in mechanical engineering who worked as REU participant.

Authors:

Efrem Dana Milwaukee School of Engineering
Subha Kumpaty Milwaukee School Of Engrg
Jordan Weston Milwaukee School of Engineering