Fused Filament Fabrication (FFF) is a widely adopted additive manufacturing technique, yet its mechanical performance is highly dependent on process parameters, particularly nozzle diameter and printing speed. This study evaluates the influence of these parameters on the tensile behavior of Acrylonitrile Butadiene Styrene (ABS) and Polylactic Acid (PLA), aiming to determine optimal conditions for enhanced strength. ASTM D638-Type IV specimens were printed using nozzle diameters ranging from 0.05 to 0.25 mm and speeds from 15 to 80 mm/s. For ABS, tensile strength increased from 56.46 MPa to 60.74 MPa, representing a 7.6% enhancement, as nozzle diameter increased, with the best performance observed at 0.25 mm and 45 mm/s, attributed to improved melt flow and interlayer fusion. PLA exhibited a non-linear response, reaching a maximum strength of 89.59 MPa under the same conditions, marking a 22.3% enhancement over the minimum value. The superior performance of PLA was linked to optimal thermal management that enhanced crystallinity and interlayer bonding. Fractographic analysis revealed reduced porosity and smoother fracture surfaces under optimized conditions. Overall, PLA consistently outperformed ABS across all settings, with an average tensile strength advantage of 47.5%. The results underscore the need for material-specific parameter tuning in FFF and offer practical insights for optimizing mechanical performance in applications demanding high structural integrity, including biomedical, aerospace, and functional prototyping.

This article explores the fatigue characteristics of acrylonitrile butadiene styrene (ABS) components fabricated using fused filament fabrication (FFF) additive manufacturing technology. ABS is frequently used as a polymeric thermoplastic material in open-source FFF machines for a variety of engineering applications. However, a comprehensive understanding of the mechanical properties and execution of FFF-processed ABS components is necessary. Currently, there is limited knowledge regarding the fatigue behavior of ABS components manufactured using FFF AM technology. The primary target of this study is to evaluate the results of part-build directions and build orientation angles on the tensile fatigue behavior exhibited by ABS material. To obtain this target, an empirical investigation was carried out to assess the influence of building angles and orientation on the fatigue characteristics of ABS components produced using FFF. The test samples were printed in three distinct directions, including Upright, On Edge, and Flat, and with varying orientation angles ([0°, 90°], [15°, 75°], [30°, 60°], [45°]), using a 50% filling density. The empirical data suggest that, at each printing angle, the On-Edge building orientation sample exhibited the most prolonged vibrational duration before fracturing. In this investigation, we found that the On-Edge printing direction significantly outperformed the other orientations in fatigue life under cyclic loading with 1592 loading cycles when printed with an orientation angle of 15°–75°. The number of loading cycles was 290 and 39 when printed with the same orientation angle for the Flat and Upright printing directions, respectively. This result underscores the importance of orientation in the mechanical performance of FFF-manufactured ABS materials. These findings enhance our comprehension of the influence exerted by building orientation and building angles on the fatigue properties of FFF-produced test samples. Moreover, the research outcomes supply informative perspectives on the selection of building direction and building orientation angles for the design of 3D-printed thermoplastic components intended for fatigue cyclic-loading applications.