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Additive manufacturing refers to a new technology in which physical parts are directly produced from a computer model
by incremental addition of the constituent materials. Fused deposition modeling (FDM) is one of the most common types
of additive manufacture processes. The ultimate mechanical performance of FDM printed parts is a function of the
interlayer bond quality. Current literature however focuses only on the phenomenological evolution of standard
mechanical properties (such as tensile and bending) as a function of printing conditions. Such studies do not provide
direct information about the interlayer adhesion and in-practice failure characteristics. In this work, a fracturemechanics-
based methodology was used to characterize the fracture resistance of FDM 3D printed Acrylonitrile
Butadiene Styrene (ABS) samples as a function of nozzle and bed temperatures. Double cantilever beam (DCB)
specimens was printed in such pattern that the applied load exerted only tensile opening stresses at the crack front. This
facilitated the measurement of crack growth under pure mode-I condition. A finite element model was then used to
obtain the J-integral strain energy release rate values, as a measure of the fracture resistance. Since the crack propagated
at the interlayer in all the cases, the fracture resistance was a direct indication of the interlayer adhesion. The results
revealed that the critical crack growth load, the actual fracture surface area (governed by printed mesostructure) and the
apparent fracture resistance all increased when the nozzle or bed temperature was increased; the nozzle temperature
showed a much stronger effect. The layer-to-layer adhesion, as reflected by the interlayer fracture resistance, did not
show monotonous increase with the temperatures and appeared to level off at higher temperatures, indicating that
complete interlayer fusion was achieved. This work provides insight into and characterizes the relationships between the
3D printing conditions, the resultant mesostructure, the apparent fracture resistance and the interlayer adhesion in FDM
3D printed materials.
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