Characterization of PC-ABS and PETG Multi-Material Laminates Fabricated by MEX Method

Area of Science:

• Materials Science
• Additive Manufacturing
• Polymer Science

Background:

• Automated filament switching in material-extrusion (MEX) 3D printing enables multi-material fabrication.
• Interfacial properties between dissimilar polymers are critical for laminate performance and failure.
• Understanding these interfaces is key to optimizing multi-material 3D printed components.

Purpose of the Study:

• To fabricate and benchmark monolithic PETG, monolithic PC-ABS, and an alternating PETG/PC-ABS laminate (COMP).
• To evaluate the mechanical properties, including tensile, flexural, and impact behavior, of these materials.
• To investigate failure mechanisms using SEM fractography.

Main Methods:

• Fabrication of monolithic PETG, PC-ABS, and COMP (0.2 mm laminae) via MEX printing.
• Mechanical testing: tensile (ISO 527-2), three-point bending, Charpy impact (ISO 179), and Shore D hardness (ISO 868).
• Scanning Electron Microscopy (SEM) for fractography.

Main Results:

• COMP exhibited superior horizontal flexural strength (159.82 ± 25.42 MPa) compared to monolithic materials.
• COMP showed enhanced Charpy impact energy absorption over PETG in the horizontal orientation.
• Tensile strength of COMP decreased by ~21-23% relative to PETG and ~5-6% relative to PC-ABS.
• SEM revealed void-assisted cracking and interfacial debonding along raster paths.

Conclusions:

• Alternating PETG/PC-ABS laminates offer improved flexural and impact performance in specific orientations.
• Tensile performance is constrained by interfacial weaknesses and porosity.
• Interfacial strengthening and porosity reduction are crucial for enhancing tensile properties in MEX multi-material prints.