This study examines the mechanical resilience and fracture dynamics of 3D-printed polymer components, focusing on the effects of raster angle orientations (0°, 45°, and 90°) on damage evolution and crack propagation. Uniaxial tensile tests on 18 specimens with initial crack lengths ranging from 3 to 10 mm, conducted using an MTS testing machine with high-resolution imaging, reveal that crack length significantly shortens fracture time, with larger cracks accelerating stress buildup and premature failure. The Chaboche model, incorporating nonlinear plasticity and cumulative damage theories, predicts damage progression, showing the 45° orientation with enhanced resistance to crack growth and extended residual life, while the 90° orientation displays the highest vulnerability. Compared to the static model, the Chaboche model better captures non-linear damage trends, with critical life fractions (βc) ranging from 0.43–0.51 (90°) to 0.47–0.6 (45°) and 0.51–0.7 (0°), highlighting the 0° orientation’s superior ductility.