Influence of 3D Printing on Safety-Critical Polymer Performance Properties

Abstract

Mechanical properties of 3D printed materials have repeatedly been demonstrated to significantly vary based on how test specimens were printed. These variations are substantially greater than for conventional injection molded samples. There is a lack of knowledge, however, on the influence of 3D printing on ignition, flammability and electrical material properties associated with UL safety standards. The influence of different combinations of material extrusion 3D print parameters and build strategies on ignition, flammability, electrical, and thermal distortion properties were investigated for two polymers, acrylonitrile-butadiene-styrene (ABS) and polyetherimide (PEI). Results from the 3D printed test specimens were compared to results measured for test specimens formed by traditional injection molding to address the knowledge gap in performance between 3D printed specimens and conventionally injected molded specimens. Based on these new findings combined with known mechanical behavior, UL will highlight an approach for acceptance of 3D printed materials and components in end products.

About the Speaker

Thomas Fabian has a doctorate in polymer science from the University of Connecticut and a Bachelor of Science in chemical engineering from Carnegie Mellon University. He joined Underwriters Laboratories in 2004 to augment UL’s polymer and textile knowledge base initially in the fire research area and more recently in the plastics as the material science R&D manager.

Tom is a multiple award winner and nationally recognized expert in smoke detection, wildland fires and upholstered furniture flammability and has served on state and federal investigation task forces. As the material science R&D manager, he leads projects to develop new test methods to better assess long term thermal aging, combustion, and electrical properties of polymers. Most recently Tom has been investigating additive manufacturing influence on polymer properties and led the introduction of the UL Blue Card which defines the additional requirements necessary to recognize plastics intended for 3D printing and 3D printed components and products.

Tom has been active leader in the textiles, fire and plastics standards development community for twenty years. He was a chairman in the American Association of Textile Colorists and Chemists (AATCC), subcommittee chair in ASTM E5 fire standards, and vice-chair for ASTM D20 plastics combustion characteristics. He also participates on the FAA task group for development of new fire tests for material certification.