Lifecycle Evaluation of Live Hinges in Automotive Polymer Fasteners Manufactured via Digital Light Processing (DLP): A Study Through Folding Test Analysis
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Keywords:
Digital Light Processing (DLP), Live Hinges, Automotive Polymer Fasteners, Fold Test Durability, 3D printAbstract
This study investigates the mechanical durability and long-term performance of live hinge
regions in automotive polymer fasteners fabricated using the Digital Light Processing (DLP) additive
manufacturing method. Live hinges, which serve as essential flexible joints in various automotive
applications, are subjected to continuous mechanical stress during operation, necessitating exceptional fold
endurance and fatigue resistance to ensure consistent functionality and longevity throughout the vehicle's
lifespan. The research systematically evaluates the material characteristics and structural performance of
these hinges by conducting repetitive folding tests, designed to replicate real-world conditions, including
thermal and mechanical stresses encountered in automotive environments.
In this context, the study explores the influence of various polymer compositions, additive formulations,
and DLP processing parameters—such as layer thickness, curing time, and post-processing treatments—on
the microstructural integrity and fold endurance of the live hinges. A comprehensive analysis is undertaken
to assess the correlation between these variables and the mechanical resilience of the hinges under cyclic
loading.
The findings of this research aim to contribute to the advancement of design methodologies and
manufacturing techniques for high-performance polymer fasteners in the automotive sector. By optimizing
the material and process parameters, the study seeks to enhance the fatigue life, wear resistance, and overall
durability of live hinges, thereby facilitating the development of more robust, efficient, and long-lasting
automotive components. This work not only provides valuable insights into the material science and
mechanical behavior of DLP-manufactured components but also offers practical guidelines for improving
design reliability in next-generation automotive fastener systems.
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