The Impact of Sequential Layer Orientation on the Flexural Behavior of 3D-Printed Polycarbonate

This study investigates the influence of sequential layer orientation on the flexural behavior of 3D-printed polycarbonate specimens. Additive manufacturing parameters, particularly build orientation, play a critical role in determining the mechanical performance of printed components. In this work, specimens were fabricated using fused deposition modeling (FDM) with different layer orientations and subsequently tested under three-point bending conditions. The results demonstrate that flexural strength and stiffness are significantly affected by the printing direction due to variations in interlayer bonding and internal microstructure. Samples printed with layers aligned parallel to the loading direction exhibited improved load-bearing capacity compared to those printed in perpendicular orientations. Failure analysis revealed that delamination between layers was the dominant failure mode in weaker configurations. The findings highlight the importance of optimizing print orientation to enhance the structural performance of polycarbonate components in engineering applications.