Integrated Evaluation of Electrical Breakdown Strength and Mechanical Properties of 3D-Printed Polymers, Supplemented by ImageJ-Based Surface Damage Analysis
Abstract
1. Introduction
2. Materials and Methods
2.1. Properties of Material
2.2. 3D Printing Process
2.3. Tensile Testing
2.4. Dielectric Breakdown Testing
3. Results and Discussion
3.1. Mechanical Properties of PLA, ABS, PETG, ASA, and PC/ABS Specimens
3.2. The Breakdown Strength of 3D-Printed Materials
3.3. Comparative Evaluation of Tensile Strength and Breakdown Strength
3.4. Comparative Evaluation of Elastic Properties and Breakdown Strength
3.5. Comparative Evaluation of Deformation Capacity and Breakdown Strength Behaviour
3.6. Quantitative Assessment of the Damage Area Using Image Analysis
4. Conclusions
- PLA specimens exhibited the highest tensile strength (46.44 MPa) and the lowest surface damage ratio (0.18%), although their dielectric breakdown strength was comparatively lower.
- ABS specimens exhibited the highest dielectric breakdown strength (30.28 kV/mm), despite comparatively low tensile strength (34.46 MPa) and restricted elongation at break.
- ASA specimens showed the lowest dielectric breakdown strength (20.35 kV/mm) and generally lower mechanical performance.
- PC/ABS specimens exhibited the highest surface damage ratio (4.14%). This indicates greater structural degradation under high-voltage conditions.
- PETG specimens provided the most balanced overall performance, combining relatively high tensile strength (38.63 MPa), the highest elongation at break (6.27%), and strong dielectric breakdown resistance (27.55 kV/mm). These characteristics identify PETG as a promising candidate among the investigated materials for 3D-printed electrical insulation applications.
- No direct or unidirectional relationship was identified between tensile strength and dielectric breakdown strength. This finding suggests that material selection for 3D-printed electrical insulation components should not rely solely on mechanical strength, but rather on a multi-parameter assessment that also considers electrical performance, deformation capacity, and damage behaviour.
Funding
Institutional Review Board Statement
Data Availability Statement
Conflicts of Interest
References
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| Specifications | PLA | ABS | PETG | ASA | PC/ABS | |
|---|---|---|---|---|---|---|
| Density (g/cm3) | ISO 1183 | 1.23 | 1.03 | 1.28 | 1.06 | 1.13 |
| Melt Flow Index (g/10 min) | 17.3 | 5.2 | 20 | 22 | 12 | |
| Heat Deflection Temperature (°C) | 55 | 95 | 80 | 95 | 120 | |
| Glass Transition Temperature (°C) | 55–60 | 95–105 | 80–85 | 100–105 | 125–135 | |
| Surface Resistance (Ohm/sq) | >1012 | >1012 | >1012 | >1012 | >1012 |
| Printing Parameter | PLA | ABS | PETG | ASA | PC/ABS |
|---|---|---|---|---|---|
| Nozzle diameter (mm) | 0.4 | 0.4 | 0.4 | 0.4 | 0.4 |
| Layer height (mm) | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 |
| Infill density (%) | 100 | 100 | 100 | 100 | 100 |
| Infill pattern | Rectilinear | Rectilinear | Rectilinear | Rectilinear | Rectilinear |
| Nozzle temperature (°C) | 220 | 283 | 240 | 275 | 283 |
| Plate temperature (°C) | 60 | 110 | 80 | 100 | 110 |
| Printing chamber temperature (°C) | - | 53 | - | 53 | 53 |
| Internal layer printing speed (mm/s) | 50 | 50 | 50 | 50 | 50 |
| Internal layer infill printing speed (mm/s) | 105 | 105 | 105 | 105 | 105 |
| External wall printing speed (mm/s) | 200 | 200 | 200 | 200 | 200 |
| Internal wall printing speed (mm/s) | 300 | 300 | 300 | 300 | 300 |
| Printing cooling fan speed (%) | 100 | - | 100 | 100 | - |
| Build plate adhesion type | Brim | Brim | Brim | Brim | Brim |
| PLA | ABS | PETG | ASA | PC/ABS | |
|---|---|---|---|---|---|
| Temperature (°C) | 50 | 65 | 60 | 65 | 65 |
| Drying time (h) | 6 | 10 | 6 | 10 | 10 |
| PLA | ABS | PETG | ASA | PC/ABS | |
|---|---|---|---|---|---|
| Et—Tensile Modulus (MPa) | 1188.41 ± 22.17 | 1109.30 ± 80.32 | 1134.31 ± 55.44 | 910.48 ± 112.06 | 924.05 ± 74.75 |
| ESec—Secant Modulus (MPa) | 1409.18 ± 123.06 | 1105.40 ± 50.82 | 1115.72 ± 27.92 | 965.63 ± 44.93 | 985.26 ± 65.77 |
| sM—Tensile Strength (MPa) | 46.44 ± 0.36 | 34.46 ± 0.42 | 38.63 ± 0.76 | 32.32 ± 0.60 | 33.10 ± 0.77 |
| εM—Elongation at Tensile Strength (%) | 3.24 ± 0.10 | 3.11 ± 0.07 | 3.80 ± 0.04 | 3.70 ± 0.09 | 4.29 ± 0.04 |
| sB—Stress at Break (MPa) | 39.65 ± 1.53 | 32.10 ± 0.89 | 28.55 ± 3.85 | 28.76 ± 1.29 | 25.04 ± 0.72 |
| εB—Elongation at Break (%) | 5.37 ± 0.15 | 4.21 ± 0.45 | 6.27 ± 0.78 | 4.94 ± 0.36 | 6.04 ± 0.22 |
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Şahin, A. Integrated Evaluation of Electrical Breakdown Strength and Mechanical Properties of 3D-Printed Polymers, Supplemented by ImageJ-Based Surface Damage Analysis. Polymers 2026, 18, 1345. https://doi.org/10.3390/polym18111345
Şahin A. Integrated Evaluation of Electrical Breakdown Strength and Mechanical Properties of 3D-Printed Polymers, Supplemented by ImageJ-Based Surface Damage Analysis. Polymers. 2026; 18(11):1345. https://doi.org/10.3390/polym18111345
Chicago/Turabian StyleŞahin, Anıl. 2026. "Integrated Evaluation of Electrical Breakdown Strength and Mechanical Properties of 3D-Printed Polymers, Supplemented by ImageJ-Based Surface Damage Analysis" Polymers 18, no. 11: 1345. https://doi.org/10.3390/polym18111345
APA StyleŞahin, A. (2026). Integrated Evaluation of Electrical Breakdown Strength and Mechanical Properties of 3D-Printed Polymers, Supplemented by ImageJ-Based Surface Damage Analysis. Polymers, 18(11), 1345. https://doi.org/10.3390/polym18111345

