Search Results (377)

Thermoplastic polyurethane (TPU) electrospun fiber membranes possess unique micro-nano structures and excellent properties. Adjusting their wettability enables the directional transportation of lubricants. A conventional method for adjusting porosity and wettability involves inducing membrane shrinkage using absolute ethanol and heat treatment. However, the shrinkage response and the corresponding changes in the tensile properties of TPU fiber membranes after induction remain unclear, limiting their applications. Thus, in this study, after being peeled off, the samples were first left to stand at room temperature (RT) for 24 h to release residual stress and stabilize their dimensions, and then treated with dehydrated ethanol at RT and high temperature, respectively, with their shrinkage behaviors observed and recorded. The results showed that TPU nanofiber membranes shrank significantly in absolute ethanol, and the degree of shrinkage was temperature-dependent. The shrinkage rates were 2% and 4% in dehydrated ethanol at room temperature and high temperature, respectively, and heating increased the shrinkage effect by 200%. These findings prove that absolute ethanol causes TPU fibers to shrink, and high temperatures further promote shrinkage. However, although the strong synergistic effect of heat and solvent accelerates shrinkage, it may induce internal structural defects, resulting in the deterioration of mechanical properties. The contraction response induced by anhydrous ethanol stimulation can be used to directionally adjust the local density and modulus of TPU nanofiber membranes, thereby changing the wettability. This approach provides new opportunities for applications in areas such as medium transportation and interface friction reduction in lubrication systems. Full article

Cranial cruciate ligament (CrCL) rupture is a common orthopedic disorder in dogs, leading to stifle joint instability and progressive osteoarthritis. This study aimed to develop and biomechanically evaluate a novel intra-articular reconstruction system designed to mimic the natural ligament and restore joint stability following CrCL excision. The system consisted of a 3D-printed thermoplastic polyurethane (TPU) graft, cerclage wire, and H-button fixation. Fourteen pelvic limbs from mature mixed-breed cadaveric dogs were used. The inclination angle, dimensions, volume, tensile strength, and elongation of the native CrCL were measured. Seven CrCL-deficient stifles were reconstructed using the proposed system and tested biomechanically. The native CrCL showed a significantly higher tensile strength than the TPU graft; however, the TPU demonstrated a greater flexibility. The reconstruction system successfully stabilized the joint and provided repeatable fixation. Significant correlations were found between CrCL volume and both age and body weight. These findings support the mechanical suitability of the proposed system for ex vivo stifle stabilization and highlight the potential of 3D-printed TPU in ligament reconstruction. Further in vivo studies are recommended to assess long-term performance, including implant integration, tissue remodeling, and clinical outcomes. Full article

Thermoplastic polyurethane (TPU) combines elastomeric and thermoplastic properties but suffers from insufficient rigidity and strength for structural applications. Herein, we developed novel carbon fiber-reinforced TPU (CF/TPU) composites filaments and utilize melt extrusion for 3D printing to maintain elasticity, while achieving enhanced stiffness and strength through multi scale-the control of fiber content and optimization of printing parameters, reaching a rigid–elastic balance. A systematic evaluation of CF content (0–25%) and printing parameters revealed optimal performance to be at 220–230 °C and 40 mm/s for ensuring proper flow to wet fibers without polymer degradation. Compared with TPU, 20% CF/TPU exhibited 63.65%, 105.51%, and 93.69% improvements in tensile, compressive, and impact strength, respectively, alongside 70.88% and 72.92% enhancements in compression and impact energy absorption. This work establishes a fundamental framework for developing rigid–elastic hybrid materials with tailored energy absorption capabilities through rational material design and optimized additive manufacturing processes. Full article

Thermoplastic polyurethanes (TPUs) have found diverse applications across different industries, which expose the material to various environmental conditions. Among these, UV radiation stands out as one of the most aggressive, leading to significant degradation in polymers. Considering this, this study explores the use of commercial additives, such as polyethylene masterbatches (MB), and their effectiveness as inhibitors of UV radiation-induced degradation. In addition, it investigates the possibility of blending high-performance polymers, such as TPU, with commodity polymers, such as polypropylenes. The prepared blends were evaluated via thermogravimetric analysis, infrared and electron microscopy, hardness and tensile strength assessments, and scanning electron microscopy before and after 320 h of exposure to accelerated aging. The findings suggest that the adequate incorporation of additives in blends can help to reduce the harmful effects caused by UV radiation on the polymeric materials. Full article

Electrospinning with sequential layer deposition has been reported for various applications such as tissue scaffolds, shape memory materials, and separations. However, the effect of layering on the mechanical properties is not fully understood. In this work, layered structures of thermoplastic polyurethane (TPU) and nylon were selected as a model system to investigate the effect of sequential layer deposition on mechanical properties. Evidence of the layered structure was indicated by scanning electron microscopy (SEM) and Fourier Transform Infrared spectroscopy (FTIR) experiments. Layering TPU with nylon resulted in a 60-fold increase in the Young’s modulus. The Young’s modulus of the layered structure was reasonably predicted by the Voigt rule of mixtures. Furthermore, the Young’s modulus changes without any statistically significant change in elongation at break compared to a single layer of nylon. Thus, the elongation at break was dictated by the stiffer material, despite being present at a lower volume fraction. Overall, electrospinning with sequential layer deposition electrospinning is an effective approach for tuning the mechanical properties and surface chemistry of electrospun materials independently, which may be of interest for applications in tissue engineering and separations. Full article

Placing printed conductive patterns onto nonplanar substrates is a challenging task. In this work, we tested a simple method for depositing inkjet-printed conductive patterns onto 3D-printed pieces with cavities and sharp edges. First, a silver nanoparticle ink was used to print conductive patterns onto a flexible and porous substrate made of electrospun polycaprolactone (PCL). Then, the printed patterns were transferred to 3D-printed pieces made of polylactic acid (PLA) by temperature-promoted adhesion. Finally, the printed patterns were cured to render them conductive. The influence of the number of printed layers on their electrical and mechanical properties was evaluated. The printed patterns were also transferred to flexible substrates, such as thermoplastic polyurethane (TPU) and polyethylene terephthalate (PET) sheets, achieving conductivity after curing. Moreover, the printed patterns were effective for modular interconnection among successive transferred patterns, since it was possible to achieve electrical contact between them during the transfer process. Full article

Microfluidic devices rely on precise fluid control to enable complex operations in diagnostics, chemical synthesis, and biological research. Central to this control are microvalves, which regulate on-chip flow but require flexible membranes for active operation. While the laser cutting of thermoplastics offers a fast, automated method for fabricating rigid microfluidic components, integrating flexible elements like valves and pumps remains a key challenge. Thermoplastic polyurethane (TPU) membranes have been adopted to address this need but are costly and difficult to procure reliably. In this study, we present commercial food-wrap film (FWF) as a low-cost, widely available alternative membrane material. We demonstrate FWF’s compatibility with laser-cut thermoplastic microfluidic devices by successfully fabricating Quake-style valves and peristaltic pumps. FWF valves maintained reliable sealing at 40 psi, maintained stable flow rates of ~1.33 μL/min during peristaltic operation, and sustained over one million continuous actuation cycles without performance degradation. Burst pressure testing confirmed robustness up to 60 psi. Additionally, FWF’s thermal resistance up to 140 °C enabled effective thermal bonding with PMMA layers, simplifying device assembly. These results establish FWF as a viable substitute for TPU membranes, offering an accessible and scalable solution for microfluidic device fabrication, particularly in resource-limited settings where TPU availability is constrained. Full article

The present study evaluates the viability of fabricating unmanned aerial vehicle (UAV) propellers using fused filament fabrication (FFF), with an emphasis on low-cost, desktop-scale production. The study’s backdrop is the recent adoption of UAVs and advancements in additive manufacturing. While the scope targets accessibility for individual and small-scale users, the results have broader implications for scalable UAV propulsion systems. The research was conducted within an experimental UAV development framework aimed at optimizing propeller performance through strategic material selection, geometrical design optimization, and additive manufacturing processes. Six propeller variants were manufactured using widely available thermoplastic polymers, including polyethylene terephthalate glycol-modified (PETG) and thermoplastic polyurethane (TPU), as well as photopolymer-based propellers fabricated using vat photopolymerization, also known as digital light processing (DLP). Mechanical and aerodynamic characterizations were performed to assess the structural integrity, flexibility, and performance of each material under dynamic conditions. Two blade configurations, a toroidal propeller with anticipated aerodynamic advantages and a conventional tri-blade propeller (Gemfan 51466-3)—were comparatively analyzed. The primary contribution of this work is the systematic evaluation of performance metrics such as thrust generation, acoustic signature, mechanical strength, and thermal stress imposed on the electrical motor, thereby establishing a benchmark for polymer-based propeller fabrication via additive manufacturing. The findings underscore the potential of polymeric materials and layer-based manufacturing techniques in advancing the design and production of UAV propulsion components. Full article

The intrinsic trade-off among sensitivity, response speed, and measurement range continues to hinder the wider adoption of flexible pressure sensors in areas such as medical diagnostics and gesture recognition. In this work, we propose a grid-structured polycaprolactone/thermoplastic-polyurethane nanofiber pressure sensor decorated with multi-walled carbon nanotubes (PCL/TPU@MWCNTs). By introducing a gradient grid membrane, the strain distribution and reconstruction of the conductive network can be modulated, thereby alleviating the conflict between sensitivity, response speed, and operating range. First, static mechanical simulations were performed to compare the mechanical responses of planar and grid membranes, confirming that the grid architecture offers superior sensitivity. Next, PCL/TPU@MWCNT nanofiber membranes were fabricated via coaxial electrospinning followed by vacuum-filtration and assembled into three-layer planar and grid piezoresistive pressure sensors. Their sensing characteristics were evaluated by simple index-finger motions and slide the mouse wheel identified. Within 0–34 kPa, the sensitivities of the planar and grid sensors reached 1.80 kPa⁻¹ and 2.24 kPa⁻¹, respectively; in the 35–75 kPa range, they were 1.03 kPa⁻¹ and 1.27 kPa⁻¹. The rise/decay times of the output signals were 10.53 ms/11.20 ms for the planar sensor and 9.17 ms/9.65 ms for the grid sensor. Both sensors successfully distinguished active index-finger bending at 0–0.5 Hz. The dynamic range of the grid sensor during the extension motion of the index finger is 105 dB and, during the scrolling mouse motion, is 55 dB, affording higher measurement stability and a broader operating window, fully meeting the requirements for high-precision hand-motion recognition. Full article

This study investigates the elastic properties of thermoplastic polyurethane (TPU) produced through Multi Jet Fusion (MJF) (HP Inc., Palo Alto, CA, USA) additive technology. TPU specimens of varying thicknesses (0.5 mm to 1.0 mm) and orientations (horizontal, diagonal, vertical) were tested. Results show anisotropic behavior, with diagonally oriented specimens exhibiting the highest elastic properties. The study emphasizes the importance of specifying the method for determining elastic properties in TPU filaments for accurate material selection in applications. The findings highlight that a single-value Young’s modulus is insufficient to describe TPU’s elastic behavior, emphasizing the need for more detailed methodological specification in material datasheets. Additionally, SEM (Thermo Fisher Scientific, Waltham, MA, USA). analysis reveals that build orientation significantly affects failure modes in MJF-printed TPU: vertical prints tend to fracture in a brittle-like manner due to interlayer delamination, whereas horizontal and diagonal orientations promote ductile failure with better layer cohesion. These insights are critical for both accurate material selection and for optimizing TPU parts in functional applications, particularly where mechanical performance under tension is essential. Full article

The leather tanning industry generates a substantial quantity of solid waste, which, in part, is discarded in the environment in landfills or incinerated. One alternative end-of-life solution is to manufacture engineered materials by forming composites with a thermoplastic polymer/binder. In this work, leather fibres (LFs) were melt-compounded into partially bio-based thermoplastic polyurethane (TPU), at leather fibre contents between 10 and 30% (TPU/LF), followed by compression moulding or 3D printing. The results showed that the incorporation of LF into the polymer matrix produced materials with a Young’s modulus comparable to that of leather. The melt extrusion processing influenced the polymer chain orientation and the resulting mechanical performance. The cyclic stress softening and abrasion resistance of the TPU/LF materials were evaluated to understand the potential of this material to be used in the footwear industry. The level of LF incorporation could be tailored to produce the specific targeted mechanical properties. This work demonstrates that LF could be used to produce materials with a high potential to be used in the fashion industry. Full article

Inspired by Scylla serrata, a novel thermoplastic polyurethane (TPU) negative Poisson’s ratio sign-switching metamaterial is proposed, and the corresponding original and gradient structures (i.e., OPSM and GPSM) are created. Numerical simulation is utilized to simulate the quasi-static and dynamic compression behavior of the proposed structures considering the rate-dependent properties, elastoplastic response, and nonlinear contact. The neo-Hookean hyperelastic constitutive model and the Prony series are adopted to model the target structures. Finite element results are validated through experimental results. Parametric studies are conducted to study the effects of gradient characteristics and loading velocities on the mechanical behavior and Poisson’s ratio of the structures. Testing results indicate that the proposed novel bioinspired structure patterns exhibit fascinating mechanical behavior and interesting negative Poisson’s ratio sign-switching characteristics, which would provide the design guidance for the development and application of bioinspired structural materials. Full article

The development of prosthetic limbs has benefited individuals who suffered amputations due to accidents or medical conditions. During the development of conventional prosthetics, several challenges have been observed regarding the functional limitations, the restricted degrees of freedom compared to an actual human limb, and the biocompatibility issues between the surface of the prosthetic limb and the human tissue or skin. These issues could result in mobility impairments due to failed mimicry of the actual stress distribution, causing discomfort, chronic pain, and tissue damage or possible infections. Especially in cases where underlying conditions exist, such as diabetes, possible trauma, or vascular disease, a failed adaptation of the prosthetic limb could lead to complete abandonment of the prosthetic part. To address these challenges, the insertion of topologically optimized parts with a biomimetic approach has allowed the optimization of the mimicry of the complex functionality behavior of the natural body parts, allowing the development of lightweight efficient anthropomorphic structures. This approach results in unified stress distribution, minimizing the practical limitations while also adding an aesthetic that aids in reducing any possible symptoms related to social anxiety and impaired social functioning. In this paper, the development of a novel anthropomorphic designed prosthetic foot with a novel Thermoplastic Polyurethane-based composite (TPU-Ground Tire Rubber 10 wt.%) was studied. The final designs contain advanced sustainable polymeric materials, gyroid lattice geometries, and Finite Element Analysis (FEA) for performance optimization. Initially, a static evaluation was conducted to replicate the phenomena at the standing process of a conventional replicated above-knee prosthetic. Furthermore, dynamic testing was conducted to assess the mechanical responses to high-intensity exercises (e.g., sprinting, jumping). The evaluation of the dynamic mechanical response of the prosthetic limb was compared to actual plantogram-derived foot pressure data during static phases (standing, light walking) and dynamic phenomena (sprinting, jumping) to address the optimal geometry and density, ensuring maximum compatibility. This innovative approach allows the development of tailored prosthetic limbs with optimal replication of the human motion patterns, resulting in improved patient outcomes and higher success rates. The proposed design presented hysteretic damping factor and energy absorption efficiency adequate for load handling of intense exercises (0.18 loss factor, 57% energy absorption efficiency) meaning that it is suitable for further research and possible upcycling. Full article

Polymer blending enhances material properties by combining different polymers, which requires careful consideration of both thermodynamic and technological compatibility. This study investigates the compatibility of polyvinyl chloride (PVC), thermoplastic polyurethane (TPU), and a bio-plasticizer in blends produced via roll milling at various mixing ratios. Compatibility and morphology were analyzed using thermally stimulated discharge (TSD), dynamic mechanical analysis (DMA), and scanning electron microscopy (SEM), while mechanical and thermal properties were assessed by mechanical testing and thermogravimetric analysis (TGA). The PVC/TPU (100/30) blend exhibited superior phase compatibility over PVC/TPU (100/50), as indicated by a single relaxation peak in TSD and DMA, along with a more homogeneous morphology and enhanced tensile properties. The PVC/TPU/bio-plasticizer (100/20/50) blend showed a well-balanced mechanical performance and improved phase homogeneity. The TSD peak maxima trends for the TPU/bio-plasticizer blend highlighted the bio-plasticizer’s dual role in enhancing flexibility at low concentrations while restricting molecular mobility at higher concentrations. TGA revealed TPU’s positive effect on PVC’s degradation profile, while the bio-plasticizer reduced thermal stability. These findings demonstrate that blending PVC, TPU, and bio-plasticizer creates compatible materials with enhanced and diverse properties, making them suitable for industrial applications. Full article

This study presents a comparative analysis of the influence of open-cell and closed-cell topologies on the manufacturing quality and resultant elasticity of 3D printed thermoplastic polyurethane (TPU) lattice structures. Lattice samples were designed based on various open-cell and closed-cell configurations, varying in unit cell size and fabricated using extrusion-based additive manufacturing (AM) techniques. A microscopic analysis was conducted to assess manufacturing defects, while mechanical compression tests were performed to characterize the elasticity of the samples. The correlation between the obtained results enabled the evaluation of the relationship between the manufacturability of lattice topologies and their stiffness. The findings reveal substantial differences in the manufacturability of the topologies, with open-cell structures exhibiting more pronounced defects. Additionally, the unit cell size and the resulting density of the samples were found to provide design advantages, as closed-cell topologies demonstrated superior load resistance. The accumulation of manufacturing defects was identified as a critical factor influencing deviations in stiffness measurements. This study establishes a foundational framework for lattice structural design, emphasizing the impact of cell topology and unit cell size on mechanical performance. The significance of this research lies in its contribution to the optimization of 3D printed TPU-based lattice structures, providing valuable insights for product design applications. Full article