Additive manufacturing of flexible thermoplastic polyurethane (TPU): enhancing the material elongation through process optimisation

Abstract Thermoplastic polyurethane (TPU) is used to produce elastomeric parts with superior wear/abrasion resistance, toughness, shock absorption properties, and flexibility, even at low temperatures. The production of this material through additive manufacturing (AM) techniques has been increasing because of the possibility of tuning the mechanical properties using structural design and build process parameters. Despite the data being limited, TPU produced by AM, mainly based on material extrusion, is much stiffer than the corresponding produced by conventional manufacturing, and, therefore, it shows a limited elongation. This study presents the mechanical characterization of TPU produced by the infrared light powder bed fusion (PBF-IrL) system (HP multi-jet fusion), which has recently been introduced. The properties are compared with TPU produced by open (3ntrA4) and closed (Markforged) material extrusion (MEX) systems. For the open FDM, the effects of the processing conditions are investigated to improve the material elongation and UTS with respect to the data reported in the literature for AM and conventional manufacturing. For this reason, an extensive and comprehensive review has been carried out. Compared to material extrusion, PBF-IrL TPU specimens showed higher Young’s modulus, but poorer A%. Considering the samples produced by MEX and compared to previous results in the literature, the properties obtained in this study are superior both in terms of UTS and A%.