Effect of raster angle on the fracture properties of additively manufactured ABS via essential work of fracture

The increasing application of additive manufacturing (AM) technology across various sectors has sparked significant interest in characterizing 3D‐printed components. An essential aspect of achieving fracture‐resistant designs is gaining a comprehensive understanding of the fracture behavior exhibited by these components. While most studies have focused on linear‐elastic fracture mechanics (LEFM), there is a lack of comprehensive studies on the post‐yield fracture behavior (PYFM) of 3D‐printed components. As a result, this study aims to fill this gap by investigating the impact of raster angle, a critical parameter influencing fracture properties and often leading to premature failures, on the fracture properties of fused deposition modeling (FDM) 3D printed acrylonitrile butadiene styrene (ABS) using essential work of fracture (EWF). Outcomes showed that by changing lay‐ups from [90]5 to [0]5, the value of we or elastic work increased by nearly 306%. Further, the maximum and minimum values of the plastic work (βwp) were for [45/−45/45/−45/45] and [90]5 lay‐ups, in order. By changing lay‐ups from [90]5 to [45/−45/45/−45/45], the value of βwp increased by approximately 216%. In addition, the fractured surfaces of tested samples are also analyzed to provide insights into the dominant failure mechanisms for different raster angles. Schematic representation of the lay‐up modes, characterizations, and results in this study.