Material extrusion based additive manufacturing is used to make three dimensional parts by means of layer-upon-layer deposition. There is a growing variety of polymers that can be processed with material extrusion. Thermoplastic polyurethanes allow manufacturing flexible parts that can be used in soft robotics, wearables and flexible electronics applications. Moreover, these flexible materials also present a certain degree of viscoelasticity. One of the main drawbacks of material extrusion is that decisions related to specific manufacturing configurations, such as the inner-structure design, shall affect the final mechanical behaviour of the flexible part. In this study, the influence of inner-structure design factors upon the viscoelastic relaxation modulus, E(t), of polyurethane parts is firstly analysed. The obtained results indicate that wall thickness has a higher influence upon E(t) than other inner-design factors. Moreover, an inadequate combination of those factors could reduce E(t) to a small fraction of that expected for an equivalent moulded part. Next, a viscoelastic material model is proposed and implemented using finite element modelling. This model is based on a generalized Maxwell model and contemplates the inner-structure design. The results show the viability of this approach to model the mechanical behaviour of parts manufactured with material extrusion additive manufacturing.

Time and temperature, besides pressure in a lesser extent, represent the most significant variables influencing the rheological behavior of viscoelastic materials. These magnitudes are each other related through the well-known Time–Temperature Superposition (TTS) principle, which allows the master curve referred to relaxation (or creep) behavior to be derived as a material characteristic. In this work, a novel conversion law to interrelate relaxation curves at different temperatures is proposed by assuming they to be represented by statistical cumulative distribution functions of the normal or Gumbel family. The first alternative responds to physical considerations while the latter implies the fulfillment of extreme value conditions. Both distributions are used to illustrate the suitability of the model when applied to reliable derivation of the master curve of Polyvinil–Butyral (PVB) from data of experimental programs. The new approach allows not only the TTS shift factors to be estimated by a unique step, but the whole family of viscoelastic master curves to be determined for the material at any temperature. This represents a significant advance in the characterization of viscoelastic materials and, consequently, in the application of the TTS principle to practical design of viscoelastic components.