New developments in additive manufacturing (AM) are enabling the use of 3D printed parts in increasingly demanding applications, such as in mechanical power transmission systems, where excellent build quality and tribological performance are required. The tribological properties of thermoplastic-based AM technologies are well knowninject, whereas the performance of photopolymer-based AM technologies is very rarely explored. This study aims to provide new insight into the tribological performance of 3D printed parts produced using vat photopolymerization (VPP). Photocurable resins based on aliphatic urethane acrylate oligomers were modified with different solid lubricants (polytetrafluoroethylene (PTFE), graphite and molybdenum disulfide (MoS₂)) and 3D printed using Digital Light Processing (DLP). The mechanical and thermal properties were studied using the tensile tests, Charpy impact tests, Shore D, and dynamic mechanical analysis (DMA). The tribological performance was studied using a Pin-on-Disk tribometer. Among the lubricants, PTFE had the highest impact on the coefficient of friction (µ) and the specific wear rate (w_s). The hybrid lubricant system (PTFE/MoS₂) resulted in excellent tribological performance, where the µ was reduced by up to 52% and w_s by up to 92%.

For a long service time, fatigue has been a typical problem that mechanical sealing materials face. How does it relate to tribological performance? In this study, filled and unfilled thermoplastic polyurethanes (TPUs) were investigated. Dumbbell and faint wait pure shear (FWPS) specimens were used to characterize the fatigue properties and crack growth rate of TPUs, respectively. Additionally, to identify the impact of temperature on fatigue tests, the tests were conducted at room temperature and 80 °C. Different tribological tests were conducted to investigate their tribological properties. Fracture surfaces from fatigue tests and worn surfaces from tribological tests were analyzed using a scanning electron microscope (SEM). Two wear models were verified to correlate between fatigue and tribological properties; one of the models is better for rough counter surfaces, while the other is advantageous if the counter surface is smooth.

Purpose: A key characteristic of powder bed fusion for polymers is that also the non-processed powder in the powder bed is exposed to elevated temperatures. This alters the properties of the remaining powder, which is compensated by refreshing the used powder with new powder. Nonetheless, it is discarded after a certain number of process iterations, which is economically and ecologically highly disadvantageous. Research works intensively to analyse and reduce the concurring effects responsible for powder ageing. This study aims to give a comprehensive overview of the cumulative changes in the powder and the printed parts when conducting several subsequent build cycles. Design/methodology/approach: New polyamide powder (PA12) was used in a total of nine subsequent build cycles with constant sintering parameters and without powder refreshing. After each iteration, the powder and parts were tested for their morphological, thermal and rheological properties. Findings: The results are related to three main changes in the powder during the build cycles: decreasing bulk density (through agglomeration), increasing melt viscosity (through polyamide post-condensation) and increasing melting peak and onset temperatures (through thermal annealing of the powder). Originality/value: Even though the ageing of PA12 powder in powder bed fusion is well-known, it is not yet fully understood. Studies are not complete and due to different ageing conditions only partially comparable. The detailed study aims to help understand the related effects of powder ageing for process-relevant properties and to show which factors require control to limit the powder ageing.

Technical thermoplastic materials (e.g., PEEK, PPA and POM) are widely used for tribological applications combined with different filler systems (e.g., glass- or carbon fibres) because of their excellent mechanical properties. The friction and wear behaviour of thermoplastics can be specifically improved by solid lubrication systems such as graphite, PTFE and MoS₂. Besides these systems, others such as WoS₂ and MnS are becoming scientifically interesting. This work investigates the influence of different solid lubricants—alternative metal sulphides and polymer-based—in combination with different glass fibre contents on the tribological behaviour of unfilled PEEK and glass fibre-filled PPA. For this purpose, compounds were produced and injection-moulded into tribological test specimens that were subsequently tested. It is particularly evident for both matrix materials that the solid lubricant SLS 22 shows a 25% wear rate reduction when compared to MoS₂ and, in addition, the proportion of fibre content in PPA shows an additional wear rate reduction by a factor of 10. The friction level could be kept at a similar level compared to the usually utilised solid lubricants. The investigations showed the potential use of metal sulphide filler systems in high-performance thermoplastic with enhanced tribological properties as alternatives to the well-established solid lubricants.