Multi-material additive manufacturing for energy-absorbing dunnage boards
Innovative composite beams using multi-material additive manufacturing (MMAM) aim to replace traditional dunnage boards, reducing damage during shipping. Using TPU and ASA materials, the beams offer enhanced stiffness and impact resistance, promising cost-effective, scalable production.
Overview
This solution introduces composite beams manufactured using multi-material additive manufacturing (MMAM) to replace traditional dunnage boards used in shipping. The beams are designed to be geometrically stiff yet energy-absorbing, significantly reducing pressure points that can damage delicate goods like membrane rolls. By utilizing a sandwich construction with a thermoplastic polyurethane (TPU) core and fiber-reinforced acrylonitrile-styrene-acrylonitrile (ASA) as facesheets, these beams can be produced in a single, continuous additive manufacturing process. The innovative design allows for targeted stiffness profiles, optimizing the beams for specific shipping requirements and reducing the risk of damage to shipped items.
Technical specifications
Key features:
- Material Composition: TPU core for high toughness and impact resistance; ASA facesheets for strength and weathering resistance.
- Manufacturing Process: Utilizes large area additive manufacturing (AM) to enable scalable production, combining multiple materials in a single process.
- Design Flexibility: Allows for direct manipulation of core geometry and material properties to achieve desired stiffness and weight reduction.
- Testing Standards: Interlayer bond strength (ASTM D5045), tensile performance (ASTM D638), flexural and compression properties (ASTM D7250, ASTM C365) evaluated.
Technology readiness level
This technology is currently at Technology Readiness Level 2 (TRL 2). It is in the early stages of development with ongoing experimental validation. Future steps include evaluating interlayer bond strength, tensile performance, and the structural integrity of full-scale prototypes to advance towards higher readiness levels.
About University of Tennessee, Knoxville
UT offers a partnership model that reduces risk, accelerates time-to-value, and supports long-term growth strategies for industry—providing an attractive platform for companies seeking to formalize collaboration and establish a long-term presence in the East Tennessee region. By aligning institutional investment with regional and national priorities, UT provides a stable and effective platform for industry collaboration, technology deployment, and sustained economic impact.
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