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<p>This study examines the combined effects of infill pattern (IP) and layer height (LH) on the mechanical and morphological properties of 3D-printed thermoplastic polyurethane (TPU-87A and TPU-95A) and acrylonitrile butadiene styrene (ABS). Mechanical characterization included tensile, compression, Charpy impact, and Izod impact testing, while scanning electron microscopy (SEM) was employed for morphological analysis. Tensile results showed that ABS achieved the highest ultimate tensile strength (UTS) of 32.98&#xa0;MPa at 0.1&#xa0;mm LH with linear IP, whereas TPU-95A and TPU-87A recorded 11.02&#xa0;MPa and 6.65&#xa0;MPa, respectively. Compressive strength analysis revealed ABS as the strongest material (73.76&#xa0;MPa), followed by TPU-95A (19.65&#xa0;MPa) and TPU-87A (13.36&#xa0;MPa). In impact tests, TPU-95A demonstrated superior toughness, reaching 50.64-53.62&#xa0;kJ/m<sup>2</sup> (Charpy) and 18.96-26.77&#xa0;kJ/m<sup>2</sup> (Izod), while TPU-87A exhibited the lowest resistance (14.57-17.63&#xa0;kJ/m<sup>2</sup> and 5.12-6.82&#xa0;kJ/m<sup>2</sup>). ABS showed moderate toughness, with concentric IP improving impact strength to 44.04&#xa0;kJ/m<sup>2</sup> (Charpy) and 65.49&#xa0;kJ/m<sup>2</sup> (Izod, achieved under concentric IP at 0.1&#xa0;mm LH). Lower LH enhanced interlayer bonding in both materials, improving energy absorption in TPU and toughness in ABS. SEM confirmed improved fusion in TPU at reduced LH, while ABS exhibited minimal interfacial defects across conditions. This study bridges the mechanical performance trends between rigid (ABS) and flexible (TPU) polymers fabricated via FFF, establishing process-structure-property correlations that distinguish strength-dominated and energy-absorbing behavior.</p>

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Mechanical Behavior of 3D Printed Acrylonitrile Butadiene Styrene and Thermoplastic Polyurethane: Effect of Infill Pattern and Layer Height

  • 期刊论文

  • 发表日期：

    2026年4月13日

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  • Mohit Kumar Pandey,
  • Renganathan Sujithra,
  • Avadesh Yadav,
  • Abhishek Kumar

摘要

This study examines the combined effects of infill pattern (IP) and layer height (LH) on the mechanical and morphological properties of 3D-printed thermoplastic polyurethane (TPU-87A and TPU-95A) and acrylonitrile butadiene styrene (ABS). Mechanical characterization included tensile, compression, Charpy impact, and Izod impact testing, while scanning electron microscopy (SEM) was employed for morphological analysis. Tensile results showed that ABS achieved the highest ultimate tensile strength (UTS) of 32.98 MPa at 0.1 mm LH with linear IP, whereas TPU-95A and TPU-87A recorded 11.02 MPa and 6.65 MPa, respectively. Compressive strength analysis revealed ABS as the strongest material (73.76 MPa), followed by TPU-95A (19.65 MPa) and TPU-87A (13.36 MPa). In impact tests, TPU-95A demonstrated superior toughness, reaching 50.64-53.62 kJ/m2 (Charpy) and 18.96-26.77 kJ/m2 (Izod), while TPU-87A exhibited the lowest resistance (14.57-17.63 kJ/m2 and 5.12-6.82 kJ/m2). ABS showed moderate toughness, with concentric IP improving impact strength to 44.04 kJ/m2 (Charpy) and 65.49 kJ/m2 (Izod, achieved under concentric IP at 0.1 mm LH). Lower LH enhanced interlayer bonding in both materials, improving energy absorption in TPU and toughness in ABS. SEM confirmed improved fusion in TPU at reduced LH, while ABS exhibited minimal interfacial defects across conditions. This study bridges the mechanical performance trends between rigid (ABS) and flexible (TPU) polymers fabricated via FFF, establishing process-structure-property correlations that distinguish strength-dominated and energy-absorbing behavior.