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Additive manufacturing offers the ability to produce complex, flexible structures from materials like thermoplastic polyurethane (TPU) for energy-absorption applications. However, selecting optimal structural parameters to achieve desired mechanical responses remains a challenge. This study aims to investigate the influence of key structural characteristics on the energy absorption and dissipation behavior and the deformation process of 3D-printed flexible TPU line-oriented structures.

Samples with varying line orientations and infill densities were fabricated using material extrusion and subjected to quasi-static compression tests. The design of experiments methodology explored the significance of design variables and their interaction effects on energy absorption and dissipation.

The results revealed a statistically significant interaction between infill density and orientation, highlighting their combined influence; however, the effect was less pronounced compared to infill density alone. For low-density structures, changing the orientation from 0°/90° to 45°/−45° and increasing infill density enhanced energy absorption and dissipation, while high-density structures exhibited unique energy absorption behavior influenced by deformation patterns and heterogeneity levels. This study facilitates the prediction of mechanical responses and selection of suitable TPU line-oriented printed parts for energy absorbing applications.

To the best of the authors’ knowledge, the present work have investigated for the first time the energy-related responses of flexible line-oriented TPU structures highlighting the distinction between the low and high density structures.