Effects of Printing Orientation on the Tensile, Thermophysical, Smoke Density, and Toxicity Properties of Ultem® 9085

Despite the impressive properties of additively manufactured products, their inherent anisotropy is a crucial challenge for polymeric parts made via fused filament fabrication (FFF). This study compared the tensile, thermophysical, smoke density, and toxicity characteristics of Ultem 9085 (a blend of polyetherimide and polycarbonate) for samples printed in various orientations (X, Y, and Z). The results revealed that mechanical properties, such as elastic modulus and tensile strength, significantly differed from the Z printing orientation, particularly in the X and Y printing layer orientations. Thermomechanical analysis revealed that Ultem 9085 had high anisotropic effects in the coefficient of thermal expansion, indicating superior thermal properties along the printing orientation. The smoke density and toxicity test results proved that Ultem 9085 complies with aviation safety standards. Smoke density tests showed that all samples, regardless of print orientation or thickness, stayed well below the regulatory limit, making them suitable for aircraft interiors.