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Cushioning is a useful material property applicable for a range of applications from medical devices to personal protective equipment. The current ability to apply cushioning in a product context is limited by the appropriateness of available materials, with polyurethane foams being the current gold standard material. The purpose of this study is to investigate additively manufactured flexible printing of scaffold structures as an alternative.

In this study, this study investigates triply periodic minimal surface (TPMS) structures, including Gyroid, Diamond and Schwarz P formed in thermoplastic polyurethane (TPU), as a possible alternative. Each TPMS structure was fabricated using material extrusion additive manufacturing and evaluated to ASTM mechanical testing standard for polymers. This study focuses attention to TPMS structures fabricated for a fixed unit cell size of 10 mm and examine the compressive properties for changes in the scaffold porosity for samples fabricated in TPU with a shore hardness of 63A and 90A.

It was discovered that for increased porosity there was a measured reduction in the load required to deform the scaffold. Additionally, a complex relationship between the shore hardness and the stiffness of a structure. It was highlighted that through the adjustment of porosity, the compressive strength required to deform the scaffolds to a point of densification could be controlled and predicted with high repeatability.

The results indicate the ability to tailor the scaffold design parameters using both 63A and 90A TPU material, to mimic the loading properties of common polyurethane foams. The use of these structures indicates a next generation of tailored cushioning using additive manufacturing techniques by tailoring both geometry and porosity to loading and compressive strengths.

This study evaluates the potential of using the material extrusion (MEX) process for recycling waste tire rubber (WTR). By investigating the process parameters, mechanical behaviour and morphological characterisation of a thermoplastic polyurethane-waste tire rubber composite filament (TPU-WTR), this study aims to establish a framework for end-of-life tire (ELT) recycling using the MEX technology.

The research assesses the impact of various process parameters on the mechanical properties of the TPU-WTR filament. Hysteresis analysis and Poisson’s ratio estimation are conducted to investigate the material’s behaviour. In addition, the compressive performance of diverse TPU-WTR triply periodic minimal surface lattices is explored to test the filament suitability for printing intricate structures.

Results demonstrate the potential of the TPU-WTR filament in developing sustainable structures. The MEX process can, therefore, contribute to the recycling of WTR. Mechanical testing has provided insights into the influence of process parameters on the material behaviour, while investigating various lattice structures has challenged the material’s capabilities in printing complex topologies.

This research holds significant social implications addressing the growing environmental sustainability and waste management concerns. Developing 3D-printed sustainable structures using recycled materials reduces resource consumption and promotes responsible production practices for a more environmentally conscious society.

This study contributes to the field by showcasing the use of MEX technology for ELT recycling, particularly focusing on the TPU-WTR filament, presenting a novel approach to sustainable consumption and production aligned with the United Nations Sustainable Development Goal 12.

Understanding the effect of process parameters on interfaces and interfacial bonding between two materials during multi-material additive manufacturing (MMAM) is crucial to the fabrication of high-quality and strong multi-material structures. The purpose of this paper is to conduct an experimental and statistical study to investigate the effect of process parameters of soft and hard materials on the flexural behavior of multi-material structures fabricated via material extrusion-based MMAM.

Sandwich beam samples composed of a soft core and hard shells are fabricated via MMAM under different printing conditions. A design of experiments is conducted to investigate the effect of the print speed and nozzle temperature on the flexural behavior of soft-hard sandwich beams. Analysis of variance and logistic regression analysis are used to analyze the significance of each process parameter. The interfacial morphology of the samples after the flexural tests is characterized. Thermal distributions during the MMAM process are captured to understand the effect of process parameters on the flexural behavior based on inter-bonding formation mechanisms.

Experimental results show that the soft-hard sandwich beams exhibited two different failure modes, including shell failure and interfacial failure. A transition of failure modes from interfacial failure to shell failure is observed as the nozzle temperatures increase. The samples that fail because of interfacial cracking exhibit a pure adhesive failure because of weak interfacial fracture properties. The samples that fail because of shell cracking exhibit a mixed adhesive and cohesive failure. The flexural strength and modulus are affected by the nozzle temperature for the hard material and the print speeds for both hard and soft materials significantly.

This paper first investigates the effect of process parameters for soft and hard materials on the flexural behavior of additively manufactured multi-material structures. Especially, the ranges of the selected process parameters are distinct, and the effect of all possible combinations of the process parameters on the flexural behavior is characterized through a full factorial design of experiments. The experimental results and conclusions of this paper provide guidance for future research on improving the interfacial bonding and understanding the failure mechanism of multi-material structures fabricated by MMAM.

This study aims to present that the chemo-responsive shape recovery of thermoplastic polyurethane (TPU) is tunable by solvents with different solubility parameters, and it is generic for chemo-responsive shape-memory polymer and its composites.

Two kinds of commercial TPU samples with different thicknesses were prepared by panel vulcanizer and injection molding (an industrial manner) to investigate their chemo-responsive shape memory properties in acetic ether and acetone.

Results showed that all of TPU films with different thicknesses can fully recover their original shapes weather they recover in acetic ether or acetone. But the recovery time of TPU films in acetone is greatly reduced, especially for the twisting samples. The residual strains of recovery TPU samples after extension reduce obviously.

The great decrement of recovery time is related to two factors. One is due to the bigger solubility parameter of acetone with higher dipole moment compared with those of acetic ether, and the other is the remained internal stress of TPU films after preparation. The internal stress is identified to have an effect on the shape-memory properties by comparing the recovery process of samples with/without annealing. The reduced residual strains of recovery TPU samples after extension is due to the increasing mobility of polymer segments after molecules of acetic ether penetrates into the polymeric chains.

This is a universal strategy to control the recovery process of shape-memory materials or composites. The underlying mechanism is generic and should be applicable to chemo-responsive shape-memory polymers or their composites.

This study aims to examine the impacts of changing US trade policy uncertainty (henceforth, TPU Index) on US bilateral trade balance with China from a nonlinear methodology perspective.

The nonlinear auto regressive distributed lag (ARDL) model, recently developed by Shin et al. (2014), is applied. This model decomposes the TPU Index series into its increases (TPU⁺) and decreases (TPU⁻) and creates two new TPU Index series.

Empirical findings indicate that increases in the TPU Index improve the US bilateral trade balance only in the short-run (no long-run impact). However, decreases in the TPU Index worsen the US trade balance in the short run but improve it in the long run. Apart from these effects detected on US–China bilateral trade balances, this empirical study draws the conclusion that changing trade policy uncertainty plays a significant determining role for bilateral trade volumes.

Decomposed TPU index with the nonlinear ARDL model enables us to examine the separate impacts of the changes in TPU⁺ and TPU⁻ indexes on US bilateral trade balance with China. Therefore, this model may discover potentially concealed-hidden true impacts of TPU index on US bilateral trade balance with this country.

The purpose of this study is to test a flexible polymer with different characteristics compared to other classical polymers mostly used in the additive manufacturing process, and to improve its mechanical properties and microstructure, by modifying different printing parameters, to make it more suitable for various industrial applications.

Seven parameters were tested, namely, nozzle temperature, bed temperature, layer thickness, printing speed, flow rate, printing time gap between two successive printed layers and raster orientation. Rheological characterizations were conducted to evaluate the influence of nozzle temperature on the melt viscosity of thermoplastic polyurethane (TPU). The effect of thermal printing parameters on the crystallinity behavior was explored. Tomographic characterizations were realized to measure the porosity and evaluate the internal structure quality of printed specimens.

Increases of the nozzle temperature, bed temperature, layer thickness and flow rate had a positive influence on the tensile strength properties of TPU with a reduction of porosity. Higher printing speeds created defects and negatively influenced the strength properties of TPU. An increase in the printing time gap between layers led to poor interlayer adhesion and decreased the tensile strength. Specimens with layers all oriented parallel to the loading direction exhibited superior mechanical properties compared to other raster orientations.

Thermoplastic elastomers are a unique class of polymers characterized by the combined thermal, chemical and mechanical properties of their elastomer and thermoplastic parts. TPU elastomer, as one of the elastomer families, has found an important position in the bioengineering and three-dimensional printing industry. This study reports a comprehensive study of the impact of additive manufacturing parameters on the properties of TPU.

Irregularly shaped architectural designs with surfaces curved in multiple directions, known as free-form designs, have gained significant public interest in recent decades. However, it is challenging to convert complex designs into real structures. This paper aims to realize free-form construction by developing a novel workflow in which additively manufactured thermoplastic polyurethane (TPU) molds are used.

The workflow is developed through mechanical tests on additively manufactured TPU specimens, determination of TPU mold design criteria and exploration of mold preparation methods. Two concrete elements with free-form geometries are fabricated using the proposed workflow.

TPU is a thermoplastic elastomer that is strong and inexpensive, making it an ideal mold material for casting complex concrete structures. An innovative workflow is developed in which TPU molds are used, appropriate release agents are selected for different concrete casting conditions and a mold subdivision method is proposed to facilitate the demolding process. Furthermore, the integrity of TPU molds can be maintained by following the proposed workflow, enabling repetitive use of molds. The fabrication of the two free-form structures shows that complex concrete members with high dimensional accuracy and excellent surface quality can be manufactured using the proposed method.

To the best of the authors’ knowledge, this is the first systematic study on using additively manufactured TPU molds for concrete casting of complex structures. The new techniques developed in this research can be applied to large-scale architectural, engineering and construction projects.

The purpose of this paper is to investigate the process of fused filament fabrication (FFF) of a compliant gripper (CG) using thermoplastic polyurethane (TPU) material. The paper studies the applicability of different CG designs and the efficiency of some design parameters.

After reviewing a number of different papers, two designs were selected for a number of exploratory experiments. Using design of experiments (DOE) techniques to identify important design parameters. Finally, the efficiency of the parts was investigated.

The research finds that a simpler design sacrifices some effectiveness in exchange for a remarkable decrease in production cost. Decreasing infill percentage of previous designs and 3D printing them, out of TPU, experimenting with different parameters yields functional products. Moreover, the paper identified some key parameters for further optimization attempts of such prototypes.

The cost of conducting FFF experiments for TPU increases dramatically with product size, number of parameters studied and the number of experiments. Therefore, all three of these factors had to be kept at a minimum. Further confirmatory experiments encouraged.

This paper addresses an identified need to investigate applications of FFF and TPU in manufacturing functional efficient flexible mechanisms, grippers specifically. While most research focused on designing for increased performance, some research lacks discussion on design philosophy, as well as manufacturing issues. As the needs for flexible grippers vary from high-performance grippers to lower performance grippers created for specific functions/conditions, some effectiveness can be sacrificed to reduce cost, reduce complexity and improve applicability in different robotic assemblies and environments.

Currently on additive manufacturing, extensive research is directed toward mitigating the main challenges associated with multi-material in fused filament fabrication which has a weak bonding strength between dissimilar materials. Low interfacial bonding strength leads to defects, anisotropy and temperature gradient in materials which negatively impact the mechanical performance of the multi-material prints. The purpose of this study was to assess the performance of different interface geometry designs in terms of the mechanical properties of the specimens.

Tensile test specimens were printed using: mono-material without a boundary interface, mono-material with the interface geometries (Face-to-face; U-shape; T-shape; Dovetail; Encapsulation; Mechanical interlocking; and Overlap) and multi-material with the interface geometries. The materials chosen with high and low compatibility were Tough polylactic acid (PLA) and TPU.

The main results of this study indicate that the interface geometries with the mechanical constriction between materials provide better structural integrity to the specimens. Moreover, in the case of the mono-material parts, the most effective interface design was the mechanical interlocking for both Tough PLA and TPU. On the other hand, in the case of multi-material specimens, the encapsulation showed the highest ultimate tensile strength, whereas the overlap and T-shape presented more robust bonding.

This study examines the mechanical performance, particularly tensile strength, strain at break, Young’s modulus and yield strength of different interface designs which were not studied in the previous studies.

The purpose of the paper is to study the dyeing process of three-dimensional-printed (3DP) fabrics, and then study the wearability of the fabrics before and after dyeing to provide a feasible dyeing method of 3DP clothes.

In this regard, the thermoplastic polyurethane (TPU) was applied during the process of 3DP. Then, the imitation twill weave (ITW) was printed with fused deposition modeling (FDM) technology using TPU and the suspension of Disperse Blue 2BLN (as a dye) was prepared. After that, the single factor analysis and orthogonal experiment of dyeing were combined to obtain the optimized dyeing process. And then, ITW fabrics were dyed through the weak acid-low temperature dyeing method. In the end, in order to discuss the wearability of ITW fabrics, the dyeing experiments, including permeability, wrinkle recovery angle, bending rigidity, crock fastness and washing colorfastness were carried out.

The surface morphology of TPU before and after spinning was established by field emission scanning electron microscopy (FE-SEM), which was confirmed the surface of TPU getting smoother after spinning. The wearability of the fabric after dyeing was not affected compared with before dyeing. Moreover, both colorfastness grades were above 4–5 with high colorfastness.

The article provides a method for 3DP dyeing, which can solve the problem of a single color. And the wearability demonstrates that 3DP fabrics after dyeing-based TPU have more value for clothing than before dyeing.