Effect of infill parameters in 3D printing and brake pads pattern on the strength of thermoplastic polyurethane material as a substitute for bicycle brake pads

This research is motivated by the increasing utilization of 3D print technology across various sectors. Understanding the appropriate materials is crucial for the effective application of this technology. The aim of this study is to analyse the utilization of Thermoplastic Polyurethane (TPU) material through 3D print as a replacement for bicycle brake pads. The research method involves comparing the strength and durability of TPU material through tensile and wear tests, based on different brake pad patterns, infill geometries, and infill densities in 3D print. The patterns used are derived from two conventional brake pad designs, namely the straight-pattern and the V-pattern. The infill geometries utilized are concentric, gyroid, and zigzag, with infill densities of 25%, 50%, 75%, and 100%. The tensile test results indicate that the gyroid infill geometry for the straight pattern exhibits high strength, while the concentric infill geometry for the V pattern demonstrates high strength. TPU material is found to be 3-4 times stronger than conventional brake pads. However, the wear test results show minimal difference between TPU material and conventional brake pads, but the resistance caused by TPU material is greater. Based on the post-wear test analysis of TPU brake pad shapes, the straight pattern displays better durability in retaining its shape. Both materials possess their own strengths and weaknesses, highlighting the need for further research and improvement to ensure the feasibility of this development.