Optimization and fast prototyping of polymer parts exposed to cyclic loading

Many mechatronic systems operate with parts made of polymers. This cost-effective solution is also easy to design. Manufacturing is trivial for producers who produce millions of parts. The solution is more complicated when the fatigue and loading is a significant factor. The paper describes the development of polymer parts that are loaded by cyclic operation. The number of cycles in a specific application can be around 1 million. The specific case also deals with a corrosion environment around these components. Gasses in the environment cause degradation of material and failure of parts made of specific polymers. This interaction limits the choice of suitable materials. The mechanism operates in two directions which define the opening of a valve and free turn. Two variants of elastic valves were analysed. Loading states were simulated by final element methods. Internal stresses and contact stresses were analysed. Results were compared with long-term test results. The material creep and other material properties define the function of elastic parts after thousands of cycles. The technology of mould fabrication was analysed considering simplification and general effectivity of production. Prototype valves were printed by FDM 3D printer and tested. Prototype moulds were printed by SLA 3D printer, which produces high-temperature stable polymer. This procedure shows cost-effective prototype development and test procedures.