Mechanical, Fatigue, and Thermal Characterization of ASA, Nylon 12, PC, and PC-ABS Manufactured by Fused Filament Fabrication (FFF)

Additive manufacturing has been widely adopted in industry as an alternative to traditional manufacturing processes for complex component production. In fact, a diverse range of materials, particularly polymers, can be processed using 3D printing for biomechanical applications (e.g., prosthetics). However, in-depth evaluation of these materials is necessary to determine their suitability for demanding applications, such as those involving cyclic loading. Following previous work that studied Polylactic Acid (PLA) and Polyethylene Terephthalate Glycol-modified (PETG) under experimental fatigue testing, this study examines the fatigue behaviour of other current 3D-printed polymeric materials, namely Acrylonitrile Styrene Acrylate (ASA), Polycarbonate (PC), Polyamide 12 (Nylon 12), and Polycarbonate–Acrylonitrile Butadiene Styrene (blend) (PC-ABS), for which fatigue data remain limited or even non-existent. The findings revealed performance differences on Tensile Strength (σR), Young’s Modulus and Ultimate Strain among tensile specimens made from these materials and characterised S-N curves for both high-cycle (HCF) and low-cycle (LCF) fatigue regimes at room temperature, with a tensile load ratio (R = 0.05). These results establish relationships among fatigue limit and quasi-static mechanical properties, namely 25% × σr for ASA (8 MPa), 7% × σr for PC (3.6 MPa), 17% × σr for Nylon 12 (7.4 MPa), and 15% × σr for PC-ABS (4.7 MPa), as well as between mechanical properties and preliminary potential biomechanical applications. Main conclusions were further supported by micro-computed tomography (micro-CT), which revealed levels of porosity in between 4% and 11%, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and Fourier transform infrared spectroscopy (FTIR).