Unraveling the main issues of direct sample printing and sample cutting from a sheet of tensile test samples for characterization of Material Extrusion components

This research investigates the influence of varied sample manufacturing strategies on the mechanical properties of Material Extrusion (MatExt) Additive Manufacturing components. Two procedures were investigated: direct sample printing and sample cutting from a sheet. The thickness of the samples was also varied to determine possible differences in the measurements performed. Through a comprehensive analysis involving mechanical testing, optical microscopy, and IR thermography during deposition, the study revealed significant implications of the manufacturing strategy on the thermal history and polymer chain entanglement. The results indicated that Young’s modulus and the tensile strength produced through direct printing differed from that measured on the samples made through sample cutting. At the same time, the elongation at rupture was less influenced by the manufacturing strategy. The sample thickness also influenced the fracture strength; the thicker samples were characterized by a strength of 27.9 MPa, which was higher by 23% than that of the extracted samples. The observed differences in mechanical behavior underscore the critical role of sample manufacturing strategy in determining the final mechanical properties of upright samples. Results shed light on the complex interplay between manufacturing protocols and component performance in MatExt applications.