New Approach for Extrusion Additive Manufacturing of Soft and Elastic Articles from Liquid-PVC-Based Consumable Materials

The article deals with the experimental development of a novel additive manufacturing (AM) process using a liquid consumable based on polyvinyl chloride plastisol. A conventional additive manufacturing system designed for deposition of melt filaments was converted to deposition of liquid material. Additive manufacturing with liquid plastisol enables the production of parts with low Shore A hardness and high ductility, surpassing the performance of the conventional filament process. The novel AM process enables the production of articles with a Shore A hardness of 5 to 60, and the mechanical properties of the additively manufactured articles are similar to those produced in the mold. This was achieved by varying the parameters of the AM process as well as the composition of the plastisol composition, including those filled with an inorganic filler. The application of different material distribution patterns also has a significant effect on the mechanical properties of the samples. A potential application of the investigated AM method was proposed and practically evaluated.