April Report Prepared By: Phil Brindley, Dr Ruth Goodridge, Mark East & Prof Richard Hague Loughborough University, Loughborough, UK

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1 Stratasys 4mc System Material Properties: Preliminary Investigation into the Mechanical Properties of Stratasys Polycarbonate & M3 ABS materials April 28 Report Prepared By: Phil Brindley, Dr Ruth Goodridge, Mark East & Prof Richard Hague Loughborough University, Loughborough, UK

materials April 28 Report Prepared By: Phil Brindley, Dr Ruth

2 1 Isotropic Properties of PC and M3-ABS materials built on the FDM 4mc System Isotropy tests (flexure & tensile) were performed on M3-ABS and PC samples produced using a Stratasys FDM 4mc system. Samples were built flat, on edge and in upright orientations. The build parameters and post-processing procedures used can be found in Appendices A & B. Ten samples for each condition were built using default parameters and tip size 12 before being tested in flexure and tension at 2 C. The mechanical tests were performed using the following calibrated equipment: Zwick Z3 Tensile Test Machine with 1KN load cell: Flexural and tensile tests were undertaken in accordance with the following ISO standards : ISO & 2: Plastics Determination of Tensile Properties 1996 ISO 178: Plastics Determination of Flexural Properties Isotropy Results for M3 ABS Build UTS Young's Flexural Flexural % Elongation Modulus Strength Modulus Orientation (MPa) (MPa) at Break (MPa) (MPa) Ave Flat Max Min Ave Edge Max Min Ave Upright Max Min Table 1: Tabulated isotropy results for M3 ABS

Ten samples for each condition were built using default parameters and tip size 12 before being tested in flexure and tension at 2 C.

3 Youngs Modulus UTS (MPa) Figure 1: Effect of build orientation on UTS of M3 ABS Figure 2: Effect of build orientation on Youngs Modulus of M3-ABS Page 3

4 Flexural Strength (MPa) Elongation at Break (%) Figure 3: Effect of build orientation on Elongation at Break of M3-ABS Figure 4: Effect of build orientation on Flexural Strength of M3-ABS Page 4

5 Flexural Modulus Figure 5: Effect of build orientation on Flexural Modulus of M3-ABS 1.2 Isotropy Results for PC Build UTS Young's Flexural Flexural % Elongation Modulus Strength Modulus Orientation (MPa) (MPa) at Break (MPa) (MPa) Ave Flat Max Min Ave Edge Max Min Ave Upright Max Min Table 2: Tabulated isotropy results for PC Page 5

Ave. 51. 2227.9 8.2 78.5 185.8 Flat Max 53.1 2436.7 8.9 83.3 1866.6 Min 5.1 1959.4 7.8 72.3 1754.1 Ave. 59. 2284.4 8.1 92.3 238. Edge Max 59.5 2849.

6 Youngs Modulus UTS (MPa) Figure 6: Effect of build orientation on UTS of PC Figure 7: Effect of build orientation on Young s Modulus of PC Page 6

UTS of PC 3 25 2 15 1 5 Figure 7: Effect of

7 Flexural Strength (MPa) Elongation at Break (%) Figure 8: Effect of build orientation on Elongation at Break of PC Figure 9: Effect of build orientation on Flexural Strength of PC Page 7

8 Flexural Modulus Figure 1: Effect of build orientation on Flexural Modulus of PC 2 Initial characterisation from -4 to +14 C for M3-ABS and PC materials built on the FDM 4mc System Tensile tests have been carried out to investigate the behaviour of M3-ABS and PC over a range of temperatures. All the test samples were produced using a Stratasys FDM 4mc system. Parts were produced on edge and in upright orientations. Ten samples for each condition were built using default parameters and with a tip size of 12 & and a slice thickness of.7. These were then tested at temperatures ranging from -4 to +14 C at 2 C intervals. The mechanical tests were performed using the following calibrated equipment: Zwick Z3 Tensile Test Machine with 1KN load cell: The tests were undertaken in accordance with the following ISO standard : ISO & 2: Plastics Determination of Tensile Properties 1996 Page 8

Parts were produced on edge and in upright orientations. Ten samples for each condition were built using default parameters and with a tip size of 12 & and a slice thickness of.7.

9 Youngs Modulus UTS (MPa) 2.1 Temperature Results for M3 ABS - tensile M3 ABS on edge - UTS Figure 11: Effect of temperature on UTS of M3 ABS built on edge M3 ABS on edge - Youngs Modulus Figure 12: Effect of temperature on Young s Modulus of M3 ABS built on edge Page 9

4 6 8 1 12 Figure 11: Effect of temperature on UTS of M3 ABS built on edge M3 ABS on

10 UTS (MPa) Elongation at Break (%) M3 ABS on edge - Elongation at Break Figure 13: Effect of temperature on Elongation at Break of M3 ABS built on edge M3 ABS upright - UTS Figure 14: Effect of temperature on UTS of M3 ABS built upright Page 1

Break of M3 ABS built on edge M3 ABS upright - UTS 3 25 2 15 1 5-6 -4-2 2 4

11 Elongation at Break (%) Youngs Modulus M3 ABS upright - Youngs Modulus Figure 15: Effect of temperature on Young s Modulus of M3 ABS built upright M3 ABS upright - Elongation at Break Figure 16: Effect of temperature on Elongation at Break of M3 ABS built upright Page 11

built upright M3 ABS upright - Elongation at Break 3 2.5 2 1.5 1.

12 Youngs Modulus UTS (MPa) 2.2 Temperature Results for PC - tensile PC on edge - UTS Figure 17: Effect of temperature on UTS of PC built on edge PC on edge - Youngs Modulus Figure 18: Effect of temperature on Young s Modulus of PC built on edge Page 12

6 8 1 12 14 16 Figure 17: Effect of temperature on UTS of PC built on edge PC on

13 UTS (MPa) Elongation at Break (%) PC on edge - Elongation at Break Figure 19: Effect of temperature on Elongation at Break of PC built on edge PC upright - UTS Figure 2: Effect of temperature on UTS of PC built upright Page 13

at Break of PC built on edge PC upright - UTS 3 25 2 15 1 5-6 -4-2 2 4 6 8 1

14 Elongation at Break (%) Youngs Modulus PC upright - Youngs Modulus Figure 21: Effect of temperature on Young s Modulus of PC built upright PC upright - Elongation at Break Figure 22: Effect of temperature on Elongation at Break of PC built upright Page 14

built upright PC upright - Elongation at Break 3 2.5 2 1.5 1.

15 Youngs Modulus UTS (MPa) 2.3 Comparison between build orientations Upright Edge Figure 23: Comparison of the effect of temperature on Tensile Strength of M3-ABS built upright and on edge Upright Edge Figure 24: Comparison of the effect of temperature on Young s Modulus of M3- ABS built upright and on edge Page 15

Comparison of the effect of temperature on Tensile Strength of M3-ABS built upright and on edge

16 UTS (MPa) Elongation at Break (%) Upright Edge Figure 25: Comparison of the effect of temperature on Elongation at Break of M3- ABS built upright and on edge PC - Tensile Strength upright edge Figure 26: Comparison of the effect of temperature on Tensile Strength of PC built upright and on edge Page 16

on edge PC - Tensile Strength 8 7 6 5 4 upright edge 3 2 1-6 -4-2 2 4 6 8 1 12 14 16 Figure

17 Elongation at Break (%) Youngs Modulus PC upright - Youngs Modulus Upright Edge Figure 27: Comparison of the effect of temperature on Young s Modulus of PC built upright and on edge PC upright - Elongation at Break Upright Edge Figure 28: Comparison of the effect of temperature on Elongation at Break of PC built upright and on edge Page 17

and on edge PC upright - Elongation at Break 14 12 1 8 6 Upright Edge 4 2-6 -4-2 2 4 6 8 1 12 14 16 Figure

FDM Material Properties

FDM Material Properties Details FDM Standard lead time: Layer thickness: Standard accuracy: Surface finish: Maximum part dimensions: Capacity: Materials: 4-5 days 0.25 mm (for ABS, ABSi) 0.18 0.25 mm (for ABS-M30, ABS-M30i, PC,