Printing-Path-Dominated Anisotropy in FDM-PEEK: Modulation by Build Orientation for Tensile and Shear Performance

Fused deposition modeling of polyether ether ketone offers distinct advantages for fabricating complex and lightweight structures. Although three principal build orientations theoretically exist for practical 3D engineering components, research on their effects remains limited, especially regarding the influence of the interaction between build orientation and printing path on mechanical performance. This study investigated the tensile and shear properties, as well as the failure mechanisms, of FDM-fabricated PEEK under the coupled effects of build orientation and printing path through mechanical testing, fracture morphology analysis, and statistical methods. The results indicate that the printing path exerts a dominant influence on anisotropic behavior, while the interaction between printing path and build orientation jointly governs the shear failure modes. Under identical printing paths, the elongation at break varied by up to twofold across different build orientations, reaching a maximum of 96%, whereas samples printed with W or T paths exhibited elongations at break below 5%. Although shear and tensile moduli remained largely consistent across build orientations, other mechanical properties demonstrated significant differences. Variations in cross-sectional dimensions induced by build orientation markedly affected tensile performance: the coupled effect of build orientation and printing path was found to render the path repetition frequency a critical factor in determining temperature uniformity within the printed region and the quality of interlayer interfaces, thereby constituting the core mechanism underlying anisotropic behavior. Furthermore, larger cross-sections re-duced tensile modulus but enhanced yield strength and elongation at break, highlight-ing the regulatory role of cross-sectional geometry on mechanical response. Based on these findings, a synergistic optimization strategy integrating printing path, build orientation, and tensile-shear performance is proposed to achieve tailored mechanical properties in FDM-fabricated PEEK components. This approach enables controlled enhancement of structural performance to meet diverse application requirements.