ANALYSIS OF THE POSSIBILITIES OF MANUFACTURING FUNCTIONAL ELEMENTS USING THE FFF METHOD

The article presents the course and results of research aimed at assessing the strength and practical usability of a furniture hinge additively manufactured from thermoplastic material. The research activities included: development of design assumptions, adoption of target geometry, creation of a 3D-CAD model, preliminary strength analysis in the FEM environment, prototype manufacturing using FFF method with thermoplastic material (pet-g), and conducting tests under conditions similar to real ones. The hinge geometry was based on typical market-available design solutions, while considering the specifics of the adopted manufacturing method. Strength analysis via FEM was conducted on the 3D-CAD model, allowing estimation of stress values and determination of the suitability of the developed geometry for testing on a real model. Subsequently, research models were produced using FFF technology with various infill patterns: linear 30%, hexagonal 30%, linear 60%, hexagonal 60%, and solid 100%. Bench tests were conducted to determine the maximum load-bearing capacity of the hinge under perpendicular loading to the axis and to assess hinge wear under conditions simulating real-life door usage. The results revealed that the hinge with solid infill safely carried a load of 160 kg without damage, while the hinge with hexagonal 30% infill exhibited the lowest load-bearing capacity, failing at 85 kg. To determine the hinge's durability, the clearance at two reference points on the doors was measured.