Thermoplastic polyurethane (TPU) is a polymer material that has high ductility, good biocompatibility and excellent abrasion resistance. These properties open a pathway to manufacturing functional TPU parts for applications in various fields such as aerospace engineering, medical devices and sports equipment. This study aims to investigate the mechanical properties of additively manufactured TPU material affected by three different processing parameters, including build orientation, mix ratio of the new and reused powders and post-processing. A series of material tests are conducted on TPU dumb-bell specimens. It is found that the mix ratio of the new powder is the most critical factor in improving the mechanical properties of the printed TPU parts. Compared to reused powder, new powder has better particle quality and thermal properties. Besides, build orientation is also a very important factor. TPU parts printed in flat and on-edge orientations show better tensile strength and deformability than those printed in upright orientation. In addition, post-processing is found to significantly enhance the deformability of TPU parts.

A new method is proposed for simultaneous optimization of shape, topology and crosssection of plane frames. Compliance against specified loads is minimized under constraint on structural volume. Difficulties caused by the melting nodes can be alleviated to some extent by introducing force density as design variables for defining the geometry, where the side constraints are assigned for force density to indirectly avoid the existence of extremely short members. Force density method is applied to an auxiliary cable net model with different boundary and loading conditions so that the regularity of force density matrix is ensured by positive force densities. Sensitivity coefficients of the objective and constraint functions with respect to the design variables are also explicitly calculated. After the optimal geometry of the frame is obtained, the topology is further improved by removing the thin members and combining closely spaced nodes. It is demonstrated in the numerical examples of three types of frames that rational geometry and topology can be achieved using the proposed method, and the effect of bending moment on the optimal solution is also discussed.

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