Comparative analysis of the mechanical properties of FDM and SLA 3D printed components

This study presents a comparative analysis of the mechanical and structural properties of materials fabricated using two prominent 3D printing techniques: fused deposition modelling (FDM) and stereolithography (SLA). Five materials were investigated: acrylonitrile butadiene styrene (ABS) and acrylonitrile styrene acrylate (ASA) for FDM, and Tough 2000, Rigid 10K and Elastic 50A resins for SLA. Standardised test specimens were produced and evaluated through tensile, flexural (three-point bend), impact and Vickers hardness testing, with surface morphology assessed via optical microscopy. The results showed significant variation in mechanical performance across materials and printing methods. SLA-printed Rigid 10K resin demonstrated the highest tensile and flexural stiffness, whereas FDM-printed ABS exhibited superior impact resistance. Elastic 50A resin showed exceptional elongation at break but was unsuitable for flexural testing under standard conditions. Microscope imaging revealed that SLA parts had superior surface finish and layer uniformity, while FDM prints exhibited visible layer lines and occasional voids that influenced mechanical behaviour. The findings underscore the crucial role of material selection and printing technology in attaining the desired mechanical performance, offering valuable insights for engineers and designers in additive manufacturing applications.