Fabrication of Low Durometer Vehicle Parts via 3D-Printed Dissolvable Molds

Author(s):

Derek J. Bischoff, Michael J. DeGrange, Matthew P. Ludkey, Anthony M. Clay, and Eric D. Wetzel

Abstract:

3D-printed dissolvable molds are used to fabricate low durometer parts (90A and 70A Shore hardness) required for Army ground vehicles using castable, curing polymer resins that are not amenable to direct 3D printing. Butenediol vinyl alcohol copolymer, a water-soluble polymer feedstock material for fused filament fabrication 3D printing, is used to fabricate molds for ground vehicle parts. After infusing the molds with thermosetting polyurethane resins, the material cures and the mold is dissolved in water to yield the final part. Gaspressurized chambers are used to infuse the molds and ensure low voids in the part after cure. This approach shows promise for rapidly producing vehicle parts from material feedstocks that cannot be directly 3D printed at the point of need.