Thermoplastic Materials Research Articles

One promising thermoplastic material: Poly(methyl methacrylate) and its continuous glass fiber reinforced composites by redox polymerization

AbstractRecently, thermosetting epoxy resin is expected to be substituted by thermoplastic featured from green circular economy. Poly(methyl methacrylate) (PMMA) has been well known as one promising thermoplastic resin, although its mechanical property needs to be further investigated. In this paper, the free radical polymerization of methyl methacrylate (MMA) was initiated by lauroyl peroxide/N,N‐dimethylaniline (LPO/DMA) and lauroyl peroxide/N,N‐dimethyl‐p‐toluidine (LPO/DMT) redox system at room temperature, respectively. The PMMA (n(MMA:LPO:DMA) = 200:1.2:1) exhibited excellent mechanical properties, and the tensile strength was 66.5 MPa, the bending strength was 118.0 MPa. The tensile strength increased to 78.9 MPa at −40°C, which suggested a promising application at low temperature. The resin was applied to fabricate continuous glass fiber reinforced PMMA (GF/PMMA) composites by vacuum‐assisted resin infusion. The 0° tensile strength and modulus were 1.17 and 43.7 GPa and 90° tensile strength and modulus were 48.3 MPa and 13.2 GPa, respectively. The mechanical properties of GF/PMMA composites are higher than GF/epoxy. Moreover, PMMA resin and glass fiber can be recycled from GF/PMMA composites by MMA as solvent, which is more energy‐efficient and environment‐friendly. This work is of great significance for preparing sustainable resin and composites.Highlights GF/PMMA composites were fabricated by vacuum perfusion. GF/PMMA composites showed higher mechanical properties than GF/epoxy. GF/PMMA composite was recycled with MMA and closed‐loop recovery was achieved.

Characterize the high-temperature steady-state rheological behavior and Arrhenius activation of PEEK via strain rate jump tensile tests

Polyetheretherketone (PEEK) is a high-performance thermoplastic polymer with diverse industrial applications, such as aerospace, automotive, electronics, and medical devices. However, systematic research on its high-temperature rheological characteristics is inadequate. In this study, strain rate jump tensile tests were introduced to examine the steady-state rheology phenomena and strain rate sensitivity of PEEK at four different temperatures and nine different strain rates. Theoretical analysis based on the free volume theory and the Arrhenius law was also carried out to further analyze the transition of PEEK from Newtonian flow to non-Newtonian flow. Results indicate that PEEK materials exhibit a transition from Newtonian flow to non-Newtonian flow similar to metal materials at high temperatures. The transition point from Newtonian flow to non-Newtonian flow is marked by the emergence of steady-state rheology and its characteristic stress. Theoretical analysis demonstrates that the transition of PEEK is in accordance with the Arrhenius low. Moreover, its apparent activation energy (1.42 eV) is significantly lower than that of metal materials (5.28 eV), indicating a lower energy barrier and an easier transition. The strain rate sensitivity index correlates negatively with rising temperatures, especially at lower rates. This study enhances understanding of PEEK's rheological characteristics at high temperatures, aiding the development and application of high-performance thermoplastic materials.

Modeling the elastoplastic behavior of agave fiber prior and after its incorporation within a thermoplastic matrix: Analysis of the fiber aspect ratio on the mechanical properties

Modeling the elastoplastic behavior of agave fiber prior and after its incorporation within a thermoplastic matrix: Analysis of the fiber aspect ratio on the mechanical properties

Simulation and mechanical testing of 3D printing shin guard composite materials

ABSTRACT This study critically examines the composite material's mechanical properties and performance for 3D-printed shin guards. It contains a thermoplastic polymer matrix with short carbon fibre reinforcement. Shin guard stress and deformation under impact loading were modelled using FEA models. The composite material was 3D-printed and tested for tensile, flexural, and impact properties. The entire cycle of FEA models and careful mechanical testing allows for the development and evaluation of new composite materials and designs. The finite element analysis, such as maximum von Mises stress, is 2890.5 MPa. The carbon fibre-reinforced composite's mechanical properties, including tensile strength, flexural strength, and impact resistance, showed a considerable improvement over those of the unreinforced polymer. The solid design could be heavier and less adaptable than the pattern. Compared to unreinforced polymers, carbon fibre improves strength, stiffness, and impact resistance for the 3D-printed composite. This result thus proves that 3D-printed carbon fibre-reinforced composites could make superior sports protective equipment like shin guards. The FEA calculations and extensive mechanical testing provide a dependable framework for creating and testing these new composite materials and systems.

Cytotoxicity assessment of eluates from vacuum-forming thermoplastics.

This study aimed to evaluate possible cytotoxic effects of thermoplastic materials commonly used for occlusal splints and orthodontic appliances. Seven thermoplastics were included: three variants of the Essix sheets (C+, Plus, and Tray Rite; Dentsply Sirona), three thermoplastics (Bleach Heavy, Splint, and X-Heavy; Cavex Holland) and Invisalign (Align Technology). Cylindrical specimens (n = 24; 10mm diameter) were incubated in cell culture medium for 24h and 14 days. After incubation, the medium was collected, serially diluted, and dosed to primary human gingival fibroblasts in triplicate. Medium processed like the samples was used as negative control. Cell viability was evaluated by XTT and LDH assay to assess metabolic activity and membrane integrity, respectively. Next, cell cycle was assessed with flow cytometry after exposing HGFs to undiluted extracts. The 24-hour and 14-day extracts did not evoke cytotoxicity after 24-hour incubation. No significant differences in cell viability (one-way ANOVA, p > 0.05 ) in the XTT and LDH assays or in cell cycle distribution between the different materials (two-way ANOVA, p > 0.05 ). The thermoplastics tested in the study showed no evident in-vitro cytotoxic effects. Further investigation should focus on determining which compounds are released from thermoplastic materials and assessing potential toxicity related to exposure to these compounds. Our study adds to the growing body of evidence on the biocompatibility of dental thermoplastics. This can aid clinical decision-making, as thermoplastics are expected to be safe to use in terms of cytotoxicity.

Wear behavior of all-ceramic micro end mills in micro milling of PMMA

Micro milling is a state-of-the-art micro manufacturing method employed, for instance, in the context of prototyping applications. Due to the high specific cutting forces and small tool diameters inherent to micro milling, tool wear represents a significant challenge for the fabrication of large, high-quality structures. In conventional cutting applications, ceramic tool substrates have been demonstrated to exhibit greater wear resistance than cemented carbides. In the case of micro milling of polymethylmethacrylate (PMMA), all-ceramic micro end mills made from zirconia (Y-TZP) have been observed to exhibit less tool wear than common cemented carbide micro end mills. In previous experiments, these tools exhibited a feed per tooth-dependent wear behavior, regardless of the spindle speed employed. The objective of this study was to investigate the wear behavior of the all-ceramic micro end mills at higher feeds per tooth (up to 7.5 µm) and spindle speeds (up to 110,000 rpm) in PMMA. The objective was to fully characterize the interactions between the all-ceramic micro end mills and the milling parameters for this thermoplastic workpiece material. The wear at the cutting edge was quantified by analyzing the topography with an atomic force microscope, and the results were correlated with the cutting forces and process outcomes. The results were found to be highly sensitive to the spindle speed used, with higher speeds leading to higher temperatures in the cutting zone and thus softening of the PMMA material. In general, micro milling parameters of 110,000 rpm and a feed per tooth of 5 µm resulted in significantly reduced tool wear with no adverse effect on surface quality when micro milling PMMA with all-ceramic micro end mills.

Starch-calcium inclusion complexes: Optimizing transparency, anti-fogging, and fluorescence in thermoplastic starch

With the increasing demand for anti-fogging transparent material and environmental concern, developing sustainable intrinsically hydrophilic and anti-fogging thermoplastic material is important. In this work, thermoplastic starch (TPS) films with good anti-fogging and optical properties were prepared via coordinative interactions with calcium chloride (CaCl2), zinc chloride (ZnCl2) and magnesium chloride (MgCl2). Among them, TPS with the incorporation of CaCl2 exhibited excellent anti-fogging and high optical transparency. Notably, the haze of TPS-0.2Ca just increased from 2.5 % to 3.8 %, with transparency remaining robust at 80 %. FTIR, XPS and 2D-WAXD results demonstrated the formation of inclusion complexes between Ca2+ and hydroxyl groups, which could modulate the hydrophobicity and hydrophilicity of TPS. Moreover, DMA, POM, and AFM results revealed that the formation of starch-calcium inclusion complex was crucial for achieving uniform intensity distribution, reduced crystalline areas, minimized light scattering, and decreased surface roughness, thereby contributing to the high transparency and low haze of TPS-Ca. Furthermore, TPS-Ca samples exhibited inherent fluorescent properties under UV light, showing the potential as disposable and eco-friendly fluorescence materials. This work provides new insights into design of sustainable TPS-based materials that combine robust antifogging performance with advanced optical property.

Sustainable Thermoplastic Material Selection for Hybrid Vehicle Battery Packs in the Automotive Industry: A Comparative Multi-Criteria Decision-Making Approach

This research study employs a comparative Multi-Criteria Decision-Making (MCDM) approach to select optimal thermoplastic materials for hybrid vehicle battery packs in the automotive industry, addressing the challenges posed by high-temperature environments. Through a detailed evaluation of materials based on criteria such as thermal stability, mechanical strength, chemical resistance, and environmental impact, the research identifies materials that enhance battery efficiency, longevity, and vehicle performance. Utilizing SWARA-ARAS, SWARA-EDAS, and SWARA-TOPSIS methods, the study systematically assesses and ranks various polymers, providing recommendations that prioritize safety, performance, and sustainability. The findings offer valuable insights for manufacturers in making informed material selection decisions, contributing to the advancement of sustainable automotive technologies. This research not only highlights the importance of material selection in the context of hybrid vehicle battery packs but also sets a foundation for future studies to explore emerging materials and decision-making frameworks, aiming to further enhance the efficiency and sustainability of hybrid vehicles.

Simulating the induction welding process of thermoplastic composite materials for aircraft structures

Purpose This paper aims to use two different numerical approaches to simulate the induction welding process for a hybrid thermoplastic material, and the results have been validated experimentally. Design/methodology/approach The first approach used a numerical model that combines electromagnetism, heat transfer and solid mechanics in the same numerical environment using Hexagon Marc software. Simultaneously, a computationally efficient approach combined steady-state electromagnetism results at specific intervals in the Ansys EM suite with heat transfer and solid mechanics in Ansys Workbench. Findings The results from both numerical approaches showed a strong correlation with the experimental findings. Originality/value The current research offers valuable insights into enhancing induction welding procedures within the aerospace industry, as well as across broader industrial applications. The synergistic combination of numerical simulations and experimental validation served as a robust framework for future research endeavors aimed at enhancing the efficiency, reliability and quality of thermoplastic welding techniques.

The Effects of Laser-Assisted Winding Process Parameters on the Tensile Properties of Carbon Fiber/Polyphenylene Sulfide Composites.

Currently, there is limited research on the in situ forming process of thermoplastic prepreg tape winding, and the unclear impact of process parameters on mechanical properties during manufacturing is becoming increasingly prominent. The study aimed to investigate the influence of process parameters on the mechanical properties of thermoplastic composite materials (CFRP) using laser-assisted CF/PPS winding forming technology. The melting point and decomposition temperature of CF/PPS materials were determined using DSC and TGA instruments, and based on the operating parameters of the laser-assisted winding equipment, the process parameter range for this fabrication technology was designed. A numerical model for the temperature of laser-heated CF/PPS prepreg was established, and based on the filament winding process setup, the heating temperature and tensile strength were simulated and tested. The effects of process parameters on the heating temperature of the prepreg and the tensile strength of NOL rings were then analyzed. The non-dominated sorting genetic algorithm (NSGA-II) was employed to globally optimize the process parameters, aiming to maximize winding rate and tensile strength. The results indicated that core mold temperature, winding rate, laser power, and their interactions significantly affected mechanical properties. The optimal settings were 90 °C, 418.6 mm/s, and 525 W, achieving a maximum tensile strength of 2571.51 MPa. This study provides valuable insights into enhancing the forming efficiency of CF/PPS-reinforced high-performance engineering thermoplastic composites.

Modelling the time-dependent mechanical properties of thermoplastic and thermosetting polymers with Gumbel distribution functions

In this paper, we propose a simple modelling method that accurately describes the time-dependent viscoelastic behaviour of thermoplastic and thermosetting solid polymers. We performed short-term creep and stress relaxation tests on representative samples of three major classes of polymers: an amorphous, a semi-crystalline thermoplastic and a thermosetting polymer. Then, to investigate the relationship between the model parameters and the material composition, we also tested thermoplastic matrix composites with different plasticiser contents. From the short-term tests, master curves were constructed with the use of the time–temperature superposition principle. Then, the temperature dependence of the obtained shift factors was described using the Arrhenius model. The resulting creep compliance and relaxation modulus master curves were normalised and modelled with a two-parameter cumulative Gumbel distribution function (CDF) and its complementary distribution function (CCDF). For the creep and stress relaxation master curves, the median error of modelling was less than 16 % and 16.5 % in all cases, respectively. Furthermore, it was less than 2 % for the thermosetting polymer, making this model an excellent tool for describing the creep and stress relaxation behaviour of thermosetting systems. In the case of the plasticised composites, we found a strong relationship between the material composition and the location parameter of the Gumbel model. Based on this, we developed a method that can be used to estimate the evolution of the creep compliance curve for any arbitrary OLA content (between 0 wt% and 16 wt%) at any desired temperature (between 22 °C and 70 °C).

Nanodiamond Nano-Reinforcements in Thermoplastic (Polyamide, Polyimide, Polystyrene) Nanocomposites—Essential Characteristics and Technicalities

Nanodiamonds are unique spherical carbon nano-entities having the advantages of very high surface area and high optical, thermal, wear and strength characteristics. Like other carbonaceous nanoparticles (like fullerene, graphene or carbon nanotube), nanodiamond nano-reinforcements have been investigated for the significant types of polymeric matrices (such as thermosets, thermoplastics, rubbers) nanocomposites. Consequently, this overview was planned to systematically describe the current scientific status of the nanodiamonds reinforced thermoplastic nanomaterials. In this regard, polyamide/nanodiamonds, polyimide/nanodiamonds and polystyrene/nanodiamonds nanocomposites have been fabricated using the facile solution, in-situ and melt mixing techniques. We suggest that including nanodiamonds in polyamides and polyimides increased their engineering characteristics, like mechanical properties and thermal stability, of the resulting nanocomposites due to a distinct interface formation and their compatibilization effects toward these matrices. Correspondingly, including nanodiamonds in polystyrene has been observed to increase the intrinsically low strength/toughness features of this polymer. Predominantly, nano-reinforcement and miscibility effects of the nanodiamonds with the polystyrene and their mutual matrix-nanofiller synergies were responsible to improve the overall microstructural and physical properties of the resulting nanocomposites. As per our analysis, the research reports so far on the important categories of the nanodiamonds reinforced thermoplastic matrix nanocomposites have shown important technical applications in the fields of high-tech coatings, membranes and energy devices.

Material Selection and Design for Assembly Applied in the Development of an Energy Generating Device

This study used the Design for Assembly (DFA) and material selection methods as tools to aid the development of a conceptual design of a functional device to transform alternate movement into rotational movement on the axis of a microgenerator. Also, material selection software was used to define the most suitable thermoplastic materials for some components of the projected device, focusing both on performance and low cost. There was a considerable reduction in the number of parts in the set from the basic device (prototype), which had 47 parts, to the conceptual design I, with 34 parts, and the conceptual design II, with 14 parts. The total mass of the set was also considerably reduced, from 160 grams for the basic device to 57.01 grams in the conceptual design I and, finally, 18.30 grams in the conceptual design II. Of thermoplastic materials analysed, considering a selection focused only on performance the most promising candidate, with an ideal set of properties is PEEK. But for a selection that considers the price, that is one of the key variables in the materials selection for most products, PEEK shows is prohibitively price.

Fracture behavior of 3D-printed thermoplastics—A dilemma of fracture toughness versus fracture energy

The Material Extrusion (ME) technique in 3D printing facilitates the production of thermoplastic materials with diverse cellular or lattice-like infill geometries, enabling the creation of lightweight, high-performance materials. This study investigates the influence of infill geometry and relative density on the fracture behavior of 3D-printed thermoplastics produced through ME. Polylactic acid (PLA) is used as the model material, with unit cell geometries-square, triangle, and Kagome-and relative densities ranging from 0.4 to 0.8 explored. Tensile tests are first conducted to determine in-plane elastic moduli in two orthogonal directions, accounting for unit cell anisotropy. These results are employed in effective fracture energy calculations. Compact tension fracture tests follow, quantitatively characterize crack growth characteristics in both directions. In both tests, digital image correlation method is used to measure full field strain distributions. Three significant findings emerge. First, there is a power scaling relationship between Elastic Modulus and relative density across all unit cells, with Kagome exhibiting the highest correlation constant. Triangle and Kagome unit cells show negligible orthotropic responses in perpendicular directions for varying relative densities. Second, the relationship between nondimensional fracture toughness and relative density follows a similar scaling law, with minor variations depending on unit cell type. The correlation factor slightly dependens on unit cell geometry but remains around 3 across the the examined relative density range. Third, considering the dissipation of inelastic fracture energy, both triangle and Kagome unit cell geometries demonstrate an order of magnitude higher effective fracture energy (i.e., crack growth resistance) compared to the square unit cell. This is associated with toughening mechanisms such as crack deflection and bifurcation. These findings highlight the disparity between fracture toughness and effective fracture energy in assessing the fracture resistance of 3D-printed thermoplastics, clearly demonstrating that fracture toughness alone is insufficient for a comprehensive assessment. The proposed scaling laws provide predictive insights into the fracture toughness of polymeric materials produced via the ME method.

A scanning electron microscope evaluation of surface roughness of different clear aligners – A comparative in-Vitro study

Clear aligner are thermoplastic polyurethane materials which produces small increments of tooth movements by each aligner tray. Clinical effectiveness of the treatment largely depend on the mechanical properties of the material. The use of scanning electron microscopy (SEM) in invitro environment allows to evaluate the surface morphology of the aligners The aim of the study is to compare the surface roughness of different types of clear aligners after thermoforming and after invitro aging. A sample of 15 aligners from Group A (DURAN), Group B (ERKODUR), Group C (MONOFLEX) were taken for this study. After screening the subjects were scanned by intraoral scanner and STL file were imported to Maestero 3D software. Then resin models were printed and aligners were fabricated in the models by thermoforming machine. The first set of aligners were scanned by Scanning Electron Microscope and another set of aligners were placed in chewing simulator for simulating intraoral environment. Then the second set of aligners were sent for SEM evaluation. Mean comparison of surface roughness and root mean square surface roughness was compared by paired t test and comparison among the groups was done by one way ANOVA test. The surface roughness of both aligners increased after thermoforming. This could be due to thermoforming process which could be due to temperature variation. After the ageing of the aligners in the invitro environment, there is homogenous and smooth layer of the aligner surfaces which could be due to adhesion of biofilm and polishing effect by chewing strokes.

Experimental investigation on low‐velocity impact performance of carbon fiber reinforced polyether ether ketone thermoplastic composite materials in room and elevated temperature

AbstractCarbon fibers woven‐ply reinforced polyether ether ketone (C/PEEK) thermoplastic composites are widely used in aerospace and high‐tech industries because of their exceptional resistance to low‐velocity impact. In this paper, experimental investigation is carried out to determine the low‐velocity impact performance of C/PEEK laminates at room temperature (RT) and high temperature (90°C and 150°C) environments. Both macroscopic and microscopic analyses are applied to examine the influence of temperature on the mechanical response and damage mode of the material. The attention of this investigation is on impact parameters such as maximum contact force, energy absorption rate, indentation depth, and damage mode. The findings show significant changes in material stiffness, rate of energy absorption, and indentation depth with rising temperature. Temperature variations have a notable effect on the PEEK matrix plasticity, C/PEEK composite interlaminar properties, crack initiation and propagation, and damage mode at the overlaps of warp and weft fibers, resulting in a transition from brittle to ductile failure.Highlights Experimental investigation is carried out to study the low‐velocity impact performance of C/PEEK. The effects of impact energy and environmental temperature on the low‐velocity impact performance of C/PEEK are investigated. The mechanism of how environmental temperature affects the damage mode of C/PEEK is investigated.

Fabrication of a 3D Printer Filamnet Extruder

3D printing, an additive manufacturing process, transforms digital designs into physical objects by layering material. This mechanization adds consecutive layers to build up the complete entity, resulting in a 3D object. It develops objects progressively to formulate the preferred look. Filaments are the main component in a die cast model (FDM) 3D printer, these are thermoplastic substances that are injected through a hot die to form the object. These filaments are available in different types such as PLA, ABS, PETG, HDPE each of which has specific characteristics that offer different applications and material options in 3D printing. This paper depicts about fabricating and developing a design of a 3D filament extruder that can produce 1.75 mm diameter filaments from recycled HDPE material. The extruder consists of a motor, a speed controller, a cylinder, a hopper, band heaters, a thermocouple, a temperature controller, a fan, a nozzle and a winder. This system works in the correct temperature range of 350-370 degrees Celsius for melting thermoplastic materials (recycled HDPE). Extruder function is to feed the material from the nozzle into the hot cylinder. A motor screw pushes the metal into the nozzle, where it becomes the filament. This filament is then injected onto a substrate for later use in 3D printing. The temperature is determined using thermocouples and a temperature controller, which ensures optimal extraction conditions. A fan is designed to quickly cool the removed filament. The objective of this research is to create an economical as well as efficient filament to produce high quality filaments. Extruder performance is evaluated based on filament diameter consistency, material penetration and energy efficiency.

Evaluation of Mechanical Properties of Composite Material with a Thermoplastic Matrix Reinforced with Cellulose Acetate Microfibers.

Low-density polyethylene (LDPE) has been widely used in various applications due to its flexibility, lightness, and low production cost. However, its massive use in disposable products has raised environmental concerns, prompting the search for more sustainable alternatives. This study aims to investigate the mechanical properties achievable in a composite material utilizing low-density polyethylene (LDPE), potato starch (PS), and cellulose microfibrils (MFCA) at loadings of 0.05%, 0.15%, and 0.30%. Initially, the cellulose acetate microfibrils (MFCA) were produced via an electrospinning process. Subsequently, a dispersive mixture of the aforementioned materials was created through the extrusion and pelletizing process to form pellets. These pellets were then molded by injection molding to produce test specimens in accordance with ASTM D 638, the standard for tensile strength testing. The evaluation of the properties was conducted through mechanical tensile tests (ASTM D638), hardness tests (ASTM D 2240), melt flow index (ASTM D1238), and scanning electron microscopy (SEM). This study determined the influence of cellulose acetate microfibril loadings below 0.3% as reinforcement within a thermoplastic LDPE matrix. It was demonstrated that these microfibrils, due to their length-to-diameter ratio, contribute to an enhancement in the mechanical properties.

Experimental and numerical analysis of new thermoplastic composite mandrels

In the field of aerospace, the application of carbon fiber composite parts is increasing year by year. As an important factor in the manufacturing of composite parts, tools play a crucial role in the manufacturing accuracy of composite parts, and composite tools have higher accuracy to better meet the manufacturing requirements. In this study, the properties of the novel thermoplastic composite mandrel of the new polymethyl methacrylate matrix are further investigated and a model is proposed to simulate the curing and spring back process of the composite part with the proposed composite mandrel. In detail, the glass transition temperature test and dynamic frequency test were carried out for the thermoplastic composite mandrel. The material constitutive equation of the thermoplastic composite mandrel was constructed based on the experimental data, and the accuracy of the constitutive equation of thermoplastic matrix material was verified by tensile experiments of matrix materials under constant strain conditions. Finally, the simulation result is compared with the fabricated part, and the effectiveness of the proposed method has been verified. This proved that the developed constitutive model of thermoplastic composite mandrel can effectively predict the curing deformation of composite parts with complex structures.

Characterisation of 3D-printable thermoplastics to be used as tissue-equivalent materials in photon and proton beam radiotherapy end-to-end quality assurance devices

Objective. To investigate the potential of 3D-printable thermoplastics as tissue-equivalent materials to be used in multimodal radiotherapy end-to-end quality assurance (QA) devices. Approach. Six thermoplastics were investigated: Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate Glycol (PETG), Polymethyl Methacrylate (PMMA), High Impact Polystyrene (HIPS) and StoneFil. Measurements of mass density ( ρ ), Relative Electron Density (RED), in a nominal 6 MV photon beam, and Relative Stopping Power (RSP), in a 210 MeV proton pencil-beam, were performed. Average Hounsfield Units (HU) were derived from CTs acquired with two independent scanners. The calibration curves of both scanners were used to predict average ρ, RED and RSP values and compared against the experimental data. Finally, measured data of ρ, RED and RSP was compared against theoretical values estimated for the thermoplastic materials and biological tissues. Main results. Overall, good ρ and RSP CT predictions were made; only PMMA and PETG showed differences >5%. The differences between experimental and CT predicted RED values were also <5% for PLA, ABS, PETG and PMMA; for HIPS and StoneFil higher differences were found (6.94% and 9.42/15.34%, respectively). Small HU variations were obtained in the CTs for all materials indicating good uniform density distribution in the samples production. ABS, PLA, PETG and PMMA showed potential equivalency for a variety of soft tissues (adipose tissue, skeletal muscle, brain and lung tissues, differences within 0.19%–8.35% for all properties). StoneFil was the closest substitute to bone, but differences were >10%. Theoretical calculations of all properties agreed with experimental values within 5% difference for most thermoplastics. Significance. Several 3D-printed thermoplastics were promising tissue-equivalent materials to be used in devices for end-to-end multimodal radiotherapy QA and may not require corrections in treatment planning systems’ dose calculations. Theoretical calculations showed promise in identifying thermoplastics matching target biological tissues before experiments are performed.