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Two types of additive manufacturing (AM) techniques, fused filament fabrication (FFF) and selective laser sintering (SLS), were employed to fabricate specimens from three widely used AM polymers: polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), and polyamide (PA): the first two using FFF and PA using SLS. The single‐edge notch bending (SENB) test was employed to measure the mode‐I fracture toughnesses of bulk and AM specimens in three directions relative to the printing direction. Unlike their bulk counterparts, AM polymers exhibited anisotropic fracture toughness. The degree of anisotropy in FFF‐PLA was much larger than FFF‐ABS and SLS‐PA. The smallest fracture toughness value for each AM polymer was achieved along the transverse printing direction. Different AM techniques affect fracture toughness differently. For instance, FFF is shown to increase PLA's plastic deformation, while SLS reduces PA's ductility. The decrease in fracture toughness is consistently observed when transitioning from bulk polymers to AM ones, reaching as much as 75%. This study provides insights into the fracture toughness of AM parts made via popular plastics, which are crucial for designing structural parts using FFF and SLS processes. Highlights: Additively manufactured polymers always exhibit some anisotropic fracture toughnessDifferent additive manufacturing techniques affect the fracture toughness differentlyFused filament fabrication increases polylactic acid's plastic deformationBut selective laser sintering reduces polyamide's ductility [ABSTRACT FROM AUTHOR]

Unlike isotropic homogenous materials, 3D printing polymers are anisotropic in terms of their strength and fracture toughness properties, according to previous research. Therefore, the lowest strength must be accurately measured before the extensive application of any 3D printing materials. Certain 3D printing materials have been increasingly employed in large structures; therefore, the size effect of their strengths has become very important. In this work, we performed a systematic experimental investigation on the minimum strengths and size effects of four common 3D printing polymers made by fusion deposition modeling and injection molding. Three types of tensile specimens with very different cross-sectional areas were selected. For each material system, two types of specimens with different printing surface angles were employed. The results from 200 specimens demonstrated that the minimum tensile strengths in the build direction of some specimens were only 25% that of the other directions in the same specimens, and 59% of the injection-molded specimens composed of the same material. No general conclusion on the size effects of the tensile strengths could be made for most specimens. Only the strengths along the build direction decreased up to 72% in two types of specific specimens if their cross-sectional areas increased by 60 times. Although their strengths were anisotropic, the stiffness properties of the 3D printing polymers were isotropic. Digital image correlation measurements showed that the Young's moduli of all specimens composed of the same material were similar. A dual-notch mechanics model was employed to explain the anisotropic strengths, and a fractography analysis supported the size effect. [Display omitted] • Tensile strength along the build direction was the minimum strength. • No general conclusion on the size effects of the tensile strengths could be made. • Strengths decreased 72% in only PLA and PC specimens if their areas increased by 60 times. [ABSTRACT FROM AUTHOR]