Comparison of Mechanical Performance of 3D Printed Polymers to Injection Molding

Abstract

As 3D printing continues to grow as a viable manufacturing process, quantification of the processing options and parameters will allow for better design and modeling of printed parts, or at least clearly define the trade-offs between the different processing options. The aim of this research was to quantify the differences between injection molding and 3D printing while also quantifying the differences between professional and personal 3D printers. In both cases, quantification of the processing allows for improved understanding for design and modeling. The study was carried out by processing two materials (nylon and ABS) using recommended parameters. An injection molder, a professional grade FDM printer and a personal grade FDM printer were used to make standard coupons for both tensile and impact testing. Standard test methodologies were followed and print orientations were adjusted for comparison of print orientation on properties. The ! study resulted in four main findings: 3D printing of these polymers leads to lower mechanical performance than injection molding; performance decreases along the Z-axis for both personal and professional printing; performance along the XY-axes are very similar between the personal and the professional grade printers; and, performance along the Z-axis are significantly better on the professional printer than on the personal printer.

Advisor: Jared W. Nelson, Ph.D Industry Collaborator: Arthur Sebert (3D Matter, Brooklyn, NY)