Additive manufacturing of elastomeric foam with cell unit design for broadening compressive stress plateau

Abstract

Purpose The purpose of this paper is to provide additive manufacturing-based solutions for preparation of elastomeric foam with broaden compressive stress plateau. Design/methodology/approach Mechanic models are developed for obtaining designs of foam cell units with enhanced elastic buckling. An experimental approach is taken to fabricate the foams based on direct ink writing technique. Experimental and simulation data are collected to assist understanding of our proposals and solutions. Findings A simple tetragonal structured elastomeric foam is proposed and fabricated by direct ink writing, in which its cell unit is theoretically designed by repeating every four filament layers. The foam exhibits a broader stress plateau, because of the pronounced elastic buckling under compressive loading as predicted by the authors’ mechanic modeling. A two-stage stress plateaus as observed in the foam, being attributed to the dual elastic buckling of the cell units along two lateral directions of the XY plane during compression. Research limitations/implications Future work should incorporate more microscopic parameters to tune the elastomeric foam for mechanic performance testing on linear elastic deformation and densification of polymer matrix. Practical implications Additive manufacturing offers an alternative to fabricate elastomeric foam with controlled cell unit design and therefore mechanics. Our results comment on its broad space for development such superior cushioning or damping material in the fields of vibration and energy absorption. Originality/value This work has contributed to new knowledge on preparation of high performance elastomeric foam by providing a better understanding on its cell structure, being printed using direct ink writing machines.