Tribomechanical Behaviour and Elasto-Plastic Contact Response of 3D-Printed Versus Conventional Polymer Inserts in Robotic Gripping Interfaces

Three-dimensional printed polymers produced using Fused Deposition Modelling (FDM) exhibit directional microstructures resulting from filament paths, layer interfaces, and cellular infill, leading to mechanical and tribological responses distinct from those of homogeneous bulk materials. This study presents a comparative tribomechanical evaluation of polypropylene (PP) bulk inserts and 3D-printed polyethylene terephthalate glycol (PETG) inserts with a 30% hexagonal infill, relevant for robotic gripping applications. Progressive scratch tests were performed under loads from 5 to 100 N (150 N for PP), and profilometry was applied to quantify groove morphology, ridge formation, and displaced-volume ratios. An elasto-plastic conical indentation model was used to derive indentation pressures and elastic–plastic transition radii from groove geometry. The PETG inserts exhibited heterogeneous groove depth, intermittent ridge tearing, and friction fluctuations associated with the internal infill structure, consistent with previous findings on anisotropy and architecture-dependent behaviour in additively manufactured polymers. In contrast, bulk PP demonstrated smoother friction profiles and more stable plastic flow under increasing loads. Two functional indices—specific frictional work and ridge-to-trace volumetric ratio—are introduced to support material selection for robotic gripping systems. The results show that local contact mechanics in 3D-printed inserts are governed by print-induced structural features and can be effectively evaluated through a scratch-based elasto-plastic analysis. The methods and results presented in this work support the rational selection and design of polymer inserts for robotic gripper fingertips. The proposed scratch-based elasto-plastic evaluation framework enables manufacturers and automation engineers to compare 3D-printed and conventional materials based on friction stability, wear response, and deformation resistance. This approach can be directly applied to optimise gripping performance in industrial handling, packaging, and collaborative robotics.