An Evaluation of the Flammability of 3D Printed Part Parameters Using the Vertical Bunsen Burner Test Method

Additive manufacturing (AM), commonly referred to as three-dimensional (3D) printing, is a modern manufacturing technology that can be applied within many different areas of the aerospace industry due to its ability to produce light and durable parts with complex geometries. Aircraft manufacturers and airlines have expressed interest in the use of AM produced parts in aircraft cabins. However, AM presents new safety challenges that must be examined, including the flammability of the 3D printed part used in the aircraft cabin. Due to the different parameters used during the production process compared to traditional manufacturing methods, it was necessary to determine the effect that variations in print parameters have on the flammability of a 3D printed part. In order to accomplish this, the following print parameters were evaluated; material type, sample thickness (number of inner layers), infill percentage, infill pattern, raster width, raster angle, and print orientation. The scope of this report only includes samples produced from the Fused Filament Fabrication (FFF) AM method, a type of extrusion-based AM process. Testing was conducted using the Vertical Bunsen Burner (VBB) test methodology outlined in Chapter 1 of the Aircraft Materials Fire Test Handbook (FAA, 2023). In the first phase of testing, only a few variables in the samples were altered and the remaining variables were kept constant so that accurate comparisons between fire data could be made. Subsequently, a Design of Experiments (DOE) analysis was conducted to determine the interaction among multiple print variable combinations. Results indicate that all evaluated variables had an impact on the flammability of a 3D printed part. The three variables that were observed to have the most significant effect on data were material type, sample thickness, and infill percentage. Other factors such as raster width, raster angle, print orientation, and infill pattern were observed to produce only interaction effects in conjunction with the other print variables listed.

• Record URL:
  • https://doi.org/10.21949/1528252
• Record URL:
  • https://rosap.ntl.bts.gov/view/dot/72825
• Corporate Authors:

  Federal Aviation Administration

  William J. Hughes Technical Center
  Aviation Research Division
  Atlantic City International Airport, NJ  United States  08405

  Federal Aviation Administration

  800 Independence Avenue, SW
  Washington, DC  United States  20591
• Authors:
  • Keslar, Dan
  • Rehn, Steven
• Publication Date: 2023-12

Language

• English

Media Info

• Media Type: Digital/other
• Edition: Final Report
• Features: Appendices; Figures; Photos; References; Tables;
• Pagination: 85p

Subject/Index Terms

• TRT Terms: Aircraft cabins; Flammability; Three dimensional printing; Vehicle design; Vehicle safety
• Subject Areas: Aviation; Materials; Safety and Human Factors; Vehicles and Equipment;

Filing Info

• Accession Number: 01903892
• Record Type: Publication
• Report/Paper Numbers: DOT/FAA/TCTN-23/65
• Files: NTL, TRIS, USDOT
• Created Date: Jan 2 2024 3:51PM