Evaluation of High-Performance FFF Filaments for Structural Components in Electric Bicycle Motors

3D printing, also known as additive manufacturing (AM), has become an inexpensive way of making prototypes and functional parts through various methods of printing. Fused filament fabrication (FFF) is one of the methods of AM that allows for less complex procedures to produce a part while providing lower operational costs than other forms of AM, such as selective laser melting (SLM) and stereolithography (SLA). Therefore, FFF has become a desirable method of production for various engineering applications requiring fast-paced design change and flexible capabilities. This study focused on the evaluation of high-performance filaments for use in structural components of electric bicycle (E-Bike) motor systems requiring mechanical strength and reliability in terms of exposure to the environment. Using mechanical tests, thermal evaluations, and chemical compatibility studies, five different commercially available materials (PLA, ASA, PC, PET-CF, and PPS-CF) were tested both electrically and through finite element analysis simulating working conditions. The objective of this research study was to determine if low-cost filaments manufactured through the FFF process could provide acceptable levels of performance with regards to long-term structural, thermal, and chemical properties associated with E-Bike applications. It was concluded that PLA is only useable for dimension verification, while both ASA and PC provided moderate improvement; therefore, fiber-reinforced composite materials, particularly PPS-CF, were the superior alternative for providing higher strength, stiffness, heat deflection, and chemical resistance. It was concluded that PPS-CF provided the most reliable selection to be used in long-term load-bearing motor components supporting the notion that FFF can be effectively used to manufacture high-performance, durable, cost-effective functional parts.