Abstract
For an ergonomic and healthy sitting posture, the distribution of the seat load in the contact zone through a soft seat cushion is essential. Conventional polyurethane (PUR) foams have only a very limited ability to adapt the distribution of the seat load in the seat cushion to the individual person. In this paper, a potential analysis is conducted to show the extent to which a replacement model for PUR foams can be realized using thermoplastic polyurethane (TPU) materials in the fused-deposition modeling (FDM) process. Based on fundamental experiments and consideration of manufacturing restrictions, suitable structure families and types are investigated and characterized. The characterization is based on standards for foam testing. Grading and design parameters are presented for the use of the foam replacement model in cushioned units. This allows the replacement of PUR foam and also a customer-specific hardness grading in the context of a mass customization process chain.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Froböse, I., Sperlich, W.: Der DKV-report 2021 – Wie gesund lebt Deutschland, Deutsche Sporthochschule Köln (2021)
López-Valenciano, A., et al.: Changes in sedentary behaviour in European Union adults between 2002 and 2017. BMC Public Health 20 (2020). Article number: 1206. https://doi.org/10.1186/s12889-020-09293-1
Mergl, C.: Entwicklung eines Verfahrens zur Optimierung des Sitzkomforts in Automobilsitzen. Technische Universität München (2006)
Miller, H.: The art and science of pressure distribution (2013). https://www.hermanmiller.com/research/categories/white-papers/the-art-and-science-of-pressure-distribution/. Accessed 20 June 2022
Weißenborn, O., et al.: Deformation analysis of polymer foams under compression load using in situ computed tomography and finite element simulation methods (2016)
Paul, G., Lee, Y.J., Slattery, P.: Modelling of multilayered foams for universal seat design (2020). https://doi.org/10.3233/ATDE200030
Schramm, B., et al.: Medizintechnische Anwendungen der additiven Fertigung. In: Richard, H., Schramm, B., Zipsner, T. (eds.) Additive Fertigung von Bauteilen und Strukturen, pp. 21–40. Springer, Wiesbaden (2017). https://doi.org/10.1007/978-3-658-17780-5_2
Babamiri, B.B., et al.: Designing additively manufactured lattice structures based on deformation mechanisms. Addit. Manuf. 46, 102143 (2021). https://doi.org/10.1016/j.addma.2021.102143
Aremu, A., et al.: A voxel-based method of constructing and skinning conformal and functionally graded lattice structures suitable for additive manufacturing. Addit. Manuf. 13, 1–13 (2017)
Al-Ketan, O., Abu Al-Rub, R.K.: MSLattice: a free software for generating uniform and graded lattices based on triply periodic minimal surfaces. Mater. Des. Process. Commun. 3(6) (2021). https://doi.org/10.1002/mdp2.205
Gama, N.V., Ferreira, A., Barros-Timmons, A.: Polyurethane foams: past, present, and future. Materials 11(10), 1841 (2018). https://doi.org/10.3390/ma11101841
Breitkopf, A.: Meistgenutzte 3D-Druck-Technologie im Jahr 2021 (2021). Stand: 12.08.2021. https://de.statista.com/statistik/daten/studie/760408/umfrage/meistgenutzte-3d-druck-technologie/. Accessed 21 June 2022
Ashby, M.F., Mehl Medalist, R.F.: The mechanical properties of cellular solids. Metall. Trans. A 14(9), 1755–1769 (1983). https://doi.org/10.1007/BF02645546
Gautam, R., Idapalapati, S.: Compressive properties of additively manufactured functionally graded Kagome lattice structure. Metals 9(5), 517 (2019). https://doi.org/10.3390/met9050517
Maskery, I., et al.: Insights into the mechanical properties of several triply periodic minimal surface lattice structures made by polymer additive manufacturing. Polymer 152, 62–71 (2018). https://doi.org/10.1016/j.polymer.2017.11.049
Maconachie, T., et al.: SLM lattice structures: properties, performance, applications and challenges. Mater. Des. 183, 108137 (2019). https://doi.org/10.1016/j.matdes.2019.108137
Müller, P., Gembarski, P., Lachmayer, R.: Density-based topology optimization for a defined external state of stress in individualized endoprosthesis. Proc. Des. Soc. 2, 533–542 (2022). https://doi.org/10.1017/pds.2022.55
Beloshenko, V., et al.: Mechanical properties of flexible TPU-based 3D printed lattice structures: role of lattice cut direction and architecture. Polymers 13(17), 2986 (2021). https://doi.org/10.3390/polym13172986
Dong, G., Tessier, D., Zhao, Y.: Design of shoe soles using lattice structures fabricated by additive manufacturing. In: Proceedings of the Design Society: International Conference on Engineering Design, vol. 1, no. 1, pp. 719–728 (2019). https://doi.org/10.1017/dsi.2019.76
Maskery, I., et al.: A mechanical property evaluation of graded density Al-Si10-Mg lattice structures manufactured by selective laser melting. Mater. Sci. Eng. A 670, 264–274 (2016). https://doi.org/10.1016/j.msea.2016.06.013
Abusabir, A., Khan, M.A., Asif, M., Khan, K.A.: Effect of architected structural members on the viscoelastic response of 3D printed simple cubic lattice structures. Polymers 14(3), 618 (2022). https://doi.org/10.3390/polym14030618
Nace, S., Tiernan, J., Holland, D.P., Annaidh, A.N.: A comparative analysis of the compression characteristics of a thermoplastic polyurethane 3D printed in four infill patterns for comfort applications. Rapid Prototyping J. (2021). https://doi.org/10.1108/rpj-07-2020-0155
Yu, S., Sun, J., Bai, J.: Investigation of functionally graded TPMS structures fabricated by additive manufacturing. Mater. Des. (2019). https://doi.org/10.1016/J.MATDES.2019.108021
Lachmayer, R., Lippert, R.B.: Entwicklungsmethodik für die Additive Fertigung, 1st edn. Springer, Wiesbaden (2020). https://doi.org/10.1007/978-3-662-59789-7
Lee, K.Y., et al.: Accuracy of three-dimensional printing for manufacturing replica teeth. Korean J. Orthod. 45(5), 217–225 (2015). https://doi.org/10.4041/kjod.2015.45.5.217
DIN ISO 3386-1: Polymere Materialien, weich - elastische Schaumstoffe – Bestimmung der Druckspannungs - Verformungseigenschaften – Teil 1: Materialien mit geringen Dichten (2015)
VDI3405: Additive manufacturing processes: design rules for part production using material extrusion processes part 3.4 (2021)
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2023 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Steinnagel, C., Bastimar, C., Gembarski, P.C., Plappert, S., Müller, P., Lachmayer, R. (2023). Characterization of Additive Manufactured Structures for the Development of Foam-Replacement Cushions. In: Lachmayer, R., Bode, B., Kaierle, S. (eds) Innovative Product Development by Additive Manufacturing 2022. IPDAM 2022. Springer, Cham. https://doi.org/10.1007/978-3-031-27261-5_6
Download citation
DOI: https://doi.org/10.1007/978-3-031-27261-5_6
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-27260-8
Online ISBN: 978-3-031-27261-5
eBook Packages: EngineeringEngineering (R0)