Non-pneumatic tires have gained a lot of attention due to their advantages, including not having to worry about getting a flat tire. In this type of tire, metamaterial cells replace the pneumatic part of the tire. In general, metamaterials are formed by stacking cells together. These cells are obtained by various methods including topology optimization. Therefore, in this research, to achieve a metamaterial cell suitable for a non-pneumatic tire with the objective function of increasing compressive strength and bending fatigue life, optimization for three types of geometry including (1) square plane, (2) rectangular plane, and (3) entire circumference of tire and three types of material including polylactic acid (PLA), thermoplastic polyurethane (TPU) and void have been done. Optimization has been implemented by using MATLAB code in 2D mode. The cubic cell is obtained from extruding the optimized response of the square plane. From the optimized response of the rectangular plane, the cylindrical cell and from extruding the optimized response of the entire circumference of tire to the tire cross-section size, the main geometry of the tire has been calculated. Finally, to check the quality of 3D printing in producing cells and how they are connected, the optimal cell fabricated by the fused deposition modeling (FDM) method has been observed using a field-emission scanning electron microscopy (FE-SEM). The results show that in the optimization of the square plane, the sample with the minimum remaining weight constraint equal to 40% and in the optimization of the rectangular plane and the entire circumference of tire, the sample with the minimum remaining weight constraint equal to 60% was selected as the optimal sample. From checking the quality of 3D printing, it has been concluded that PLA and TPU materials are completely connected.

Additive manufacturing (AM) are used in several industries such as automotive, aerospace, and medical sciences. One of the most common devices used in additive manufacturing is fused deposition modeling (FDM) 3D printers. This fabrication method has different inputs that affect the quality of the parts. In this research, the bending fatigue properties of polylactic acid (PLA) biomaterial made with a 3D printer are investigated. To demonstrate the influence of printing parameters on fatigue lifetime, standard specimens with nozzle diameters of 0.2-0.6 mm, extruder temperature of 180-240°C, and print speed of 5-15 mm/s were printed. After performing fully-reversed bending fatigue tests, it was found that printed specimens at 180°C have the best fatigue lifetime in most cases. Accordingly, fatigue behavior improved by reducing the nozzle diameter. Printing at lower temperatures also improved fatigue lifetime. The printing speed affected the slope of the S-N diagram, known as the fatigue strength exponent.

In the previous work, the pure fatigue behavior of AM60 magnesium alloy (PF-AM60) was compared with the corrosion fatigue behavior of these specimens (CF-AM60). In this research, in continuation of the previous job, the pure fatigue behaviors of AM60 with polylactic acid (PLA) coating (PF-AM60-PLA) and also, corrosion fatigue behaviors of magnesium alloy with PLA coating (CF-AM60-PLA) were evaluated. Polymer coating was made by fused deposition modeling (FDM) with a 3D printer and attached to standard fatigue test specimens with a glue. Then, they were immersed in the simulated body fluid (SBF) for 27 days. In the end, a high-cycle bending fatigue test was performed on samples. The fracture surface of the samples was also observed using the field emission scanning electron microscopy (FESEM). Due to corrosion, the weight of the specimens redcued by an average of 35%. The corrosion rate decreased in the first 7 days and then increased. PF samples with coating had an average of 49% increase in fatigue lifetime. Regarding the CF samples, despite the use of a 10 times stronger solution, the fatigue lifetime of these samples decreased by only 35%. FESEM results also showed cleavage plates and striations. In addition, the separation of the glue from the coating and Mg was observed. Corrosion products including microcracks and holes were seen on the fracture surface of CF specimens, which caused stress concentration and crack growth. Holes caused by the release of gases were also observed in polymer coatings.