Multiscale Study on Fused Deposition Modeling and Stereolithography 3D Printed Parts: How to 3D Print Better?

Abstract In a century where additive manufacturing (AM), specifically 3D printing, is significantly more than a prototyping technique, there is a gap in understanding how to enhance the quality and strength of 3D printed parts. Material characterization techniques in solid mechanics are well-established. However, there is still a need to develop a material characterization regimen for 3D-printed parts from different techniques, such as fused deposition modeling (FDM) or stereolithography (SLA). In this study, we perform a comprehensive benchmarking study comparing the quality and strength of prints using FDM and SLA for a given wall thickness, infill percentage, and overhang angle. The dogbone samples printed in each configuration are tested under tensile testing to measure their rupture strength. The same polymers formed as thin films are studied at the micro-scale using atomic force microscope (AFM) measurements. The results of this study will provide a detailed guideline for both general and technical users of FDM and SLA 3D printers to optimize printing time and material strength and quality for the given condition.