Interrelationships between process parameters, cross‐sectional geometry, fracture behavior, and mechanical properties in material extrusion additive manufacturing

Abstract Additive manufacturing offers reduced lead time between design and manufacturing. Fused filament fabrication, the most common form of material extrusion additive manufacturing, enables production custom‐made parts with complex geometry. Despite numerous advantages reliability, reproducibility, achievement isotropic bulk properties in part remains challenging. We investigated tensile behavior a model polycarbonate system to explore what leads different properties, including sources ductile versus brittle fracture. utilized one factor at (OFAT) experiments (DOE), printed single road‐width boxes, performed tests on specimens from these boxes. Additionally, we characterized cross‐sections under conditions their subsequent fracture behavior. The results demonstrate that are achievable by printing high speeds, provide mechanisms explain why. Highlights Printing speeds improved mechanical properties. Printed samples undergo mix failure. Jagged path is associated superior adhesion. High layer times worse interfacial bonding.