Design and mechanical analysis of bushings made from TPU using additive manufacturing and the finite element method

The study focused on analyzing the mechanical behavior of a front suspension fork bushing for an all-terrain vehicle (ATV), manufactured using Thermoplastic Polyurethane (TPU) through additive manufacturing, specifically 3D printing. This technology enables the creation of customized designs, reduces production time, and minimizes material waste. TPU, an elastomer with remarkable physical and mechanical properties, was evaluated as a potential substitute for natural rubber, which is the primary material traditionally used for bushings in the automotive industry, especially in the production of tires, hoses, and seals. The analysis was conducted through CAD modeling and finite element simulations, subjecting the bushing to torsional and shear stresses typical of vehicular suspension systems. The results indicated that TPU could serve as a replacement material for the established requirements. Given that replacement parts are not always acquired in a timely manner, the study focuses on providing a viable alternative for the automotive industry.