Evaluation of the influence of three-dimensional printing conditions on peel resistance and surface roughness of flexible polymer-textile composites

Extensive fashion and textiles research have adopted Fused Filament Fabrication in 3D printing. However, much research has dedicated itself to experimenting with rigid materials that lack the capability to mimic conventional textile-like garments. The commercialization of Thermoplastic polyurethane/elastomers (TPU/TPE) have posed greater potentials for developing flexible polymer-textile composites (FPTC). Such materials will enable the creation of ergonomically designed textiles with optimized flexibility & elasticity aimed for garments. This study examines the influence of polymers, textile surface roughness, and nozzle temperature on peel resistance and polymer coefficient of friction/surface roughness. T-peel tests (ISO 11339:2022), cross-sectional microscopic image analysis, and a KES-FB4-A surface tester were used to evaluate the surface quality and peel resistance between polymer-textile assemblies. Our results revealed TPU-knitted combinations to demonstrate superior peel resistance owing to knitted structure’s pore structure and TPU’s lower melting temperature. Moreover, a significant increase in peel strength was found at 260 °C (above recommended printing temperature) in TPU-knitted fabrics at 3.24N/mm. While the coefficient of friction remained similar, a rougher surface quality was discovered at higher temperatures in TPU at 3.85μm warp/4.35μm weft. In TPE, the roughest surface was found at 240 °C measuring 3.65μm warp/3.37μm weft. This study fills a lack of research into FPTC by suggesting parameters for achieving an equilibrium between optimal adhesion and polymer layer surface quality.