Abstract Scope |
ULTEM 9085 is the first Federal Aviation Administration (FAA) qualified 3D printed thermoplastic, well-known for its high strength-to-weight ratio, chemical resistance, and flame retardance. However, a large difference in mechanical properties exists between traditionally manufactured high-performance thermoplastics and 3D printed materials. This study investigated the effects of print parameters on material properties through density, surface profile, scanning electron microscopy (SEM), and void analyses across various coupon geometries and build orientations. Surface microscopy findings revealed that inter- and intra-layer bonding significantly influences density and tensile performance variations. Additionally, a machine learning (ML) model was developed to analyze tensile-tested ULTEM 9085 coupons, with 3D printing parameters as inputs and critical mechanical properties—such as strength, modulus, and yield strength—as outputs. The ML model uncovered previously unknown relationships between printing parameters and mechanical properties. Overall, this research provides essential insights for optimizing additive manufacturing processes for high-performance aerospace applications. |