Abrasion Test Platform v1 – Testing Methodology

Purpose and Scope

The Abrasion Test Platform v1 is designed to evaluate the relative abrasion resistance and wear behavior of FDM-printed polymer materials under controlled and repeatable conditions. The primary purpose of the data generated is internal comparison: results are most valid when compared against other data produced using the same platform, procedure, and configuration.

While the overall test philosophy and mechanics are informed by ASTM and ISO abrasion testing practices, this methodology does not claim full compliance with any published standard. As such, results should be interpreted as comparative rather than absolute or certified.

Test Principle

Abrasion is induced by controlled, single-direction linear motion between a fixed abrasive surface and a printed polymer test coupon. A spring-loaded compliance mechanism applies normal force, allowing continuous contact as material wear progresses and compensating for changes in surface height over time.

Wear performance is evaluated through progressive thickness loss measured at defined cycle intervals, supported by mass change and qualitative surface observations.

Abrasive Surface

Each test is performed using a brand-new masonry paver as the abrasive surface. The paver material was selected to approximate real-world abrasion environments such as concrete and road surfaces, while providing sufficient rigidity and durability for extended testing.

Surface preparation and use are controlled as follows:

• A new paver is used for every individual test
• Prior to testing, the surface is dusted and cleaned using a wire brush to remove loose debris or contaminants
• No prior conditioning cycles are performed beyond this cleaning step
• During testing, the coupon sweeps across the abrasive surface on every stroke, ensuring even and complete utilization of the paver surface over the course of the test

This approach minimizes cross-test contamination and ensures consistent abrasive exposure throughout each run.

Test Coupons

Test coupons are flat-faced polymer specimens produced using FDM printing.

Key coupon characteristics:

• Flat top surface with no post-processing
• High solid top-layer count to eliminate early infill interaction
• Nominal solid top thickness of approximately 4 mm
• Consistent orientation, layer height, extrusion width, and print profile within each test series

All material details, printer settings, and coupon dimensions are recorded prior to testing.

Compliance and Normal Force Control

Normal force is applied using a spring-loaded compliance mechanism rather than fixed Z-axis positioning. This design maintains consistent contact pressure as wear occurs and helps distribute load evenly across the coupon surface.

For Abrasion Test Platform v1:

• Spring rate and preload are fixed for each test
• No active force measurement or closed-loop control is used
• Applied force is treated as a controlled but relative parameter

Motion Profile

Abrasion is generated through single-direction linear strokes.

Motion characteristics:

• Abrasion occurs in one direction only
• The return stroke is lifted to prevent reverse abrasion
• Stroke length and speed are fixed per test
• Each stroke traverses the abrasive surface fully, ensuring uniform surface utilization

All motion parameters are defined in G-code and documented as part of the test record.

Test Duration and Measurement Intervals

Each test consists of a fixed total of 1,000 abrasion strokes.

Testing is paused at defined intervals to record wear progression:

• Thickness measurements are taken every 100 strokes
• Measurements are recorded at consistent locations on the coupon to reduce variability
• Testing resumes immediately after measurement until the next interval or test completion

This stepped approach allows wear rate to be quantified over time without requiring continuous visual monitoring.

Test Execution

1. A new paver is installed and cleaned with a wire brush.
2. The test coupon is mounted securely in the fixture.
3. Compliance preload is set to the defined configuration.
4. Initial coupon mass and thickness are recorded.
5. The test is initiated and run for 1,000 strokes, pausing every 100 strokes for thickness measurement.

Data Collected

For each test, the following data is recorded:

• Material type, manufacturer, and color
• Print parameters and orientation
• Abrasive surface type (new paver per test)
• Stroke length, speed, and total cycle count
• Thickness measurements at 0, 100, 200 … 1,000 strokes
• Initial and final coupon mass
• Calculated wear rate per 100 strokes
• Qualitative observations (surface texture changes, smearing, delamination, thermal effects)

Mass change is recorded as a delta relative to the initial mass and is considered a secondary metric due to material density variation.

Data Interpretation and Limitations

Data generated using the Abrasion Test Platform v1 is intended for relative comparison within this test framework. The highest confidence is achieved when comparing materials tested using identical configurations and measurement intervals.

Limitations of the current methodology include:

• Lack of calibrated normal force measurement
• Use of a real-world abrasive surface rather than standardized test media
• Intentional deviation from full ASTM or ISO procedural compliance

Future revisions will introduce measured force feedback, expanded abrasive surface options, and improved alignment with recognized abrasion testing standards.