Mechanical characterization of new bi-material generated by additive manufacturing: IZOD test–puncture impact behaviour

Purpose The purpose of this paper is to characterize a new structural bi-material (scaffold and filler). Design/methodology/approach The bi-material has been obtained by means of an additive manufacturing system consisting of a fused filament fabrication extruder head and an epoxy resin depositor head. The new bi-material will consist of a thermoplastic material that will serve as the main structure and an epoxy resin that will serve as a filler and adhesion between layers. The creation of this new bi-material will improve the physical–chemical and mechanical properties with respect to the thermoplastic material. This paper will focus on the impact behavior of IZOD and the impact behavior of punctures. Findings The new polylactic acid (PLA) and epoxy bi-material allow improvements in toughness and puncture impact resistance compared to the PLA thermoplastic. This increase in toughness is between 20% and 30% depending on the orientation of the print. In the same way, the energy absorbed in the puncture impact test has been increased by 42%–48%. Practical implications The improvement in the impact absorption capacity of this new bi-material makes it ideal for the manufacture of medical parts in which customization, lightness and impact resistance are their main characteristics such as sports protection systems. Originality/value The originality of creating parts through additive manufacturing that combines a material generated with cold extrusion, such as epoxy resin and a material generated with hot extrusion, such as thermoplastics, lies in the unique synergy that this mixed and simultaneous technique offers. By uniting these two manufacturing methods, it allows the exploration of new physical and chemical properties in the resulting parts, taking advantage of the individual advantages of each material. This combination opens the door to the creation of components with a wider range of characteristics, from strength and durability to flexibility and temperature resistance, thus offering innovative and versatile solutions for various applications in fields such as engineering, medicine and design.