Parametric study for tensile properties of molded high-density polyethylene for applications in additive manufacturing and sustainable designs

Test specimens following ASTM D638 standards are frequently used to measure the tensile properties of reinforced and unreinforced polymers machined with traditional machining and emerging manufacturing methods (additive manufacturing/3D printing). However, designs of large engineering structures may rely on mechanical properties based on ASTM D3039 for fiber-reinforced polymer composites. This parametric study examines the scaling effects present in uniaxial tensile test specimens of molded high-density polyethylene (HDPE), with geometries ranging from Types I to IV of ASTM D638 to ASTM D3039. HDPE is a thermoplastic polymer that is recyclable, can be 3D-printed, and has a wide range of engineering applications, from bottles to pipes to radiation protection shielding. The mechanical properties test results for the molded HDPE samples are validated using a Monte Carlo simulation to estimate uncertainties for the probability distribution of maximum stress at the yield point. A Finite Element study based on the empirical model shows how the proposed approach can be adopted for design purposes. The results of this work are a useful tool to enhance confidence in the tensile mechanical properties of ASTM D638 Types II and IV geometries as statistically similar to those of ASTM D3039 samples, impacting engineering designs with traditional and emerging manufacturing methods.