NISTIR 8059 

Materials Testing 

Standards for Additive 

Manufacturing of Polymer 

Materials:

State of the Art and Standards Applicability

Aaron M. Forster
NISTIR 8059

Materials Testing Standards for 

Additive Manufacturing of Polymer 

Materials: State of the Art and 

Standards Applicability

Aaron M. Forster

This publication is available free of charge from:

http://dx.doi.org/10.6028/NIST.IR.8059
NISTIR 8059

Materials Testing Standards for 

Additive Manufacturing of Polymer 

Materials: State of the Art and 

Standards Applicability

Aaron M. Forster

Materials and Structural Systems Division

Engineering Laboratory

This publication is available free of charge from:

http://dx.doi.org/10.6028/NIST.IR.8059

May 2015

U.S. Department of Commerce 

Penny Pritzker, Secretary

National Institute of Standards and Technology 

Willie May, Under Secretary of Commerce for Standards and Technology and Director
National Institute of Standards and Technology Interagency Report 8059

54 pages (May 2015)

This publication is available free of charge from:

http://dx.doi.org/10.6028/NIST.IR.8059

 

 

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i

Abstract

Additive manufacturing (AM) continues to grow as an advanced manufacturing technique. The 

most recent industry report from Wohlers and Associates indicates AM represented $1.6B in 

revenue from parts, systems, and other supporting industries in 2012 and is expected to grow to

more than $3.5B by 2017 and to $10B by 2022. The measurement challenges for AM, whether 

the deposited material is metal or polymer, are similar. Parallels between the additive 

manufacturing for metals and polymers include: characterization of raw materials, development 

of material properties for design, in-situ process and feedback control, workflow optimization, 

and modeling final properties. The scope of this report is to analyze the current trends in polymer 

additive manufacturing and determine the applicability of current American Society for Testing 

Materials International (ASTM) and the International Standards Organization (ISO) standard test 

methods for mechanical properties and failure of polymers and polymer composites generated 

from the additive manufacturing processes. The current approach to mechanical testing standards 

utilizes existing guidelines for testing materials, but this analysis highlights the need to develop 

specific guidelines for testing AM materials. The current AM efforts at NIST towards polymers 

are supported through the Material Measurement Laboratory (MML) AM program. While this 

program is addressing critical measurement science to validate polymer physics within AM, it is 

not directly translating this knowledge into the standards required for engineering design. The 

emerging engineering and standards challenges for high performance polymers and polymer 

composites are not currently addressed by the Engineering Laboratory (EL) Additive 

Manufacturing program, which is focused on metal applications. The development of a program 

to bridge the measurement gap between molecular architecture of AM materials (MML) and 

generating engineering properties for design represents an opportunity for the EL effort.

Key words: additive manufacturing, polymer, mechanical properties, standards, testing
ii

Table of Contents

Table of Figures.............................................................................................................................iii

List of Acronyms ........................................................................................................................... iv

1. Introduction: ............................................................................................................................ 1

2. Scope: ...................................................................................................................................... 3

3. Government and Academic Support: ...................................................................................... 4

4. Materials:................................................................................................................................. 6

5. Mechanical Properties for Design: .......................................................................................... 9

6. Challenges for Mechanical Property Characterization:......................................................... 15

7. Overview of Standard Testing Methods................................................................................ 19

7.1. Tension........................................................................................................................... 19

7.2. Flexure............................................................................................................................ 19

7.3. Compression................................................................................................................... 20

7.4. Shear............................................................................................................................... 20

7.5. Creep .............................................................................................................................. 20

7.6. Fatigue............................................................................................................................ 21

7.7. Fracture Toughness........................................................................................................ 21

7.8. Impact............................................................................................................................. 22

7.9. Bearing Strength and Open Hole Compression ............................................................. 23

8. Standards Applicability Assessment ..................................................................................... 23

9. Polymer Additive Manufacturing at NIST ............................................................................ 32

10. Conclusion and Path Forward................................................................................................ 33

Acknowledgements....................................................................................................................... 35

References..................................................................................................................................... 36
iii

Table of Figures

Figure 1: Pie chart showing the types of material utilized for AM as fraction of material 

consumed by AM from a user survey. [15] .................................................................................... 7

Figure 2: Building block integration for the development of composite structures [53].............. 10

Figure 3: Building block approach for the support of composites structures in the 777 aircraft 

[53]. In this graphic durability is defined through moisture stability, temperature stability, creep 

resistance, and fatigue resistance. ................................................................................................. 11

Figure 4: Mesostructure of an ME-ABS material illustrating the porous structure that may be 

achieved based on the raster angle and bead overlap [54]............................................................ 12

Figure 5: Graphic illustrating the directionality of fibers, through z, in a fiber composite 

laminate. The orientation and number of fibers controls the performance of the composite. ...... 13

Figure 6: Three modes of crack surface displacements Mode I (opening or tensile mode), Mode 

II (sliding mode), and Mode III (tearing mode) copied from [56]................................................ 14

Figure 7: Graphical representation of process variables related to the build geometry for additive 

manufacturing. a) raster angle, b) extruded filament height and layer width, c) air gap between 

extruded filaments, d) combinations of variables (T, air gap, width, height, velocity) can increase 

the coalescence between filaments, e) the build direction can affect the load transfer between 

filaments and interfaces. ............................................................................................................... 16
iv

List of Acronyms

AMC, Additive Manufacturing Consortium – A national consortium of industry, government, 

academic, and non-profit research organizations with the mission of accelerating and advancing 

the manufacturing readiness of metal additive manufacturing technology.

AM, additive manufacturing – a process of joining materials to make objects from 3D model 

data, usually layer upon layer, as opposed to subtractive manufacturing methodologies [1].

AmericaMakes – is the National Additive Manufacturing Innovation Institute. AmericaMakes is 

focused on helping the United States grow capabilities and strength in 3D printing. It is based in 

Youngstown, Ohio and is an extensive network of more than 100 companies, non-profit 

organizations, academic institutions and government agencies [2].

ARL - Army Research Laboratory.

ASTM – American Society of Testing Materials International.

Battelle – Battelle Memorial Institute is the world’s largest nonprofit research and development 

organization.

CAD/CAM – Computer Aided Design/Computer Aided Machining.

CAMM, Consortium for Additive Manufacturing Materials – The organizational component 

of CIMP 3D. It was created from a NIST Advanced Manufacturing Technology Consortia 

(AMTech) Program grant to foster innovation in additive manufacturing.

CIMP 3D, Center for Innovative Materials Processing Through Direct Digital Deposition –

A consortium administered by Pennsylvania State University, Batelle, and Sciaky Corporation. It 

is a resource for AM technology for critical applications [3]. 

CNC, computer numerical control – indicative of computer-controlled machinery for cutting 

various hard materials. These are synonymous with subtractive manufacturing methods.

DARPA – Defense Advanced Research Projects Agency.

FDM – a material extrusion process used to make thermoplastic parts through heated extrusion 

and deposition of materials layer by layer; term denotes machines built by Stratasys, Inc [1].

ISO – International Standards Organization.

LS, laser sintering – a powder bed fusion process used to produce objects from powdered 

materials using one or more layers to selectively fuse or melt the particles at the surface, layer by 

layer, in an enclosed chamber [1].
v

NAMII, National Additive Manufacturing Innovation Institute - The pilot institute from 

NNMI established in 2012. This consortium includes 40 companies, nine research universities, 

five community colleges, and 11 nonprofit organizations. This consortium is also called 

AmericaMakes [4].

NCDMM, National Center for Defense Manufacturing and Machining – the driver of 

AmericaMakes. The mission is to deliver optimized manufacturing solutions that enhance the 

quality, affordability, maintainability, and rapid deployment of existing and yet-to-be developed 

defense systems [5]. 

NNMI, National Network for Manufacturing Innovation – A federally backed network 

established by the Revitalize American Manufacturing Act. The institutes developed under 

NNMI are intended to create a competitive, effective, and sustainable manufacturing research-tomanufacturing infrastructure for U.S. industry and academia to solve industry-relevant problems.

ME, material extrusion – an additive manufacturing process in which a material is selectively 

dispensed through a nozzle or orifice [1].

MSAM, Measurement Science for Advanced Manufacturing – A cooperative agreement 

program that solicits proposals for grants to advanced manufacturing. The program is 

administered by the National Institutes of Standards and Technology. This is the program 

developed to administer grants for the NNMI.

ONR – Office of Naval Research

ORNL – Oak Ridge National Laboratory
1

1. Introduction1: 

Additive manufacturing is a process of joining materials to make objects from 3D model data, 

usually in a layer by layer process [1, 6]. The objects are created in CAD/CAM software, 

transformed to machining instructions similar to the process for CNC machining, and each layer 

is directly fabricated on top of previous layers to create a replica of the object. In general, this 

manufacturing process is not subtractive. Multiple processes exist to create polymeric materials 

and composites, but they generally fall into three classes: material extrusion, powder bed fusion, 

and material jetting.

Material Extrusion (ME) is a process that selectively dispenses a thermoplastic polymer through 

a nozzle. Stratasys has trademarked the term fused deposition modeling (FDM®) to identify their 

systems that utilize this technique [1]. The extrusion head melts the plastic filament, extrudes

material through a nozzle, and places the resin bead onto the substrate. This is a less aggressive 

process compared to injection molding where the plastic is melted and uniformly blended using a 

screw extruder to inject the material at high pressure into a mold. There are specific challenges 

for additive manufacturing that are unique to polymeric materials. In ME, heat is used to melt a 

polymer filament and the material is directed to a specific location via a nozzle. This places a 

polymer beads or filament of a specific size and length onto the substrate. Successive beads are 

layered to create the final 3D structure. The strength of the part is generated from the deposited 

material properties and the interface between beads. The interface is important because the 

neighboring beads are at a lower temperature than the molten bead leaving the nozzle. The 

thermal gradient between the two materials will melt the existing bead and cause polymers 

molecule to diffuse across the interface. The strength of this fusion is dependent on many factors 

such as temperature gradient, polymer structure (molecular weight, branching, heat of fusion, 

glass transition temperature, etc.), and bead geometry. It is possible for this fusion to exist under 

stress prior to any mechanical loading. As the beads cool, the polymer contracts which creates a 

localized residual stress. As the performance of AM materials is increased by using semicrystalline and more rigid polymers, the physics to model interfacial strength and stress are 

different than amorphous materials. There are additional challenges such as ME surface 

roughness, void space between beads, and defects (excess material) that can initiate failure 

modes within the part under loading. The nature of the printing process and the aligned structure 

of the beads make AM parts highly anisotropic and this anisotropy may exhibit a non-linear 

dependence on processing parameters. 

Laser sintering (LS), or powder bed fusion, is a process that utilizes directed energy to melt a 

thermoplastic powder similar to the process used to generate parts from metal powders. This 

process starts with a powder bed of polymer powder of a specific layer height and temperature. 

A high powered laser is rastered across the surface to locally heat the polymer pellets. At this 

 

1 Certain commercial equipment, instruments, or materials are identified in this paper to 

foster understanding. Such identification does not imply recommendation or endorsement by 

the National Institute of Standards and Technology, nor does it imply that the materials or 

equipment identified are necessarily the best available for the purpose.
2

point, two thermal processes could occur depending on the machine design. The laser could fully 

melt the polymer pellets and allow the molten material to flow and diffuse into adjacent material. 

The second process locally heats the pellets to allow diffusion of polymer between adjacent 

pellets and layers. This is equivalent to a sintering process. In either case, the locally heated 

polymer diffuses to create a single layer within the part. A fresh layer of powder material is 

placed on top of the previous layer and the laser again melts local regions of polymer. The 

strength of parts is dependent on the ability of the process to manage thermal gradients. The 

molten material must flow into cracks adjacent to previous layers and the thermal gradient must 

be high enough to allow entanglement between neighboring polymer layers [7]. These parts tend 

to exhibit anisotropy characteristic of the laser scanning direction or build (Z) direction and can 

exhibit location dependent voids. 

The material jetting process, which is similar to early stereolithography methods used for rapid 

prototyping [8], utilizes an inkjet print head to deposit a thin layer of photopolymerizable 

polymer and initiator. Ultraviolet lamps, or similar energy source, at the print head initiate cure 

of the photopolymer layer as it is deposited [9]. Direct printing processes have challenges related 

to the chemistry of the photocurable polymers used to build parts. Localized curing may be 

inhomogeneous which leads to a range of mechanical properties throughout the part. 

Uncrosslinked material trapped within holes may plasticize or age the part causing premature 

failure [10]. 

Additive manufacturing (AM) continues to grow as an advanced manufacturing technique. The 

most recent industry report from Wohlers and Associates indicates AM represented $1.6B in 

revenue from parts, systems, and other supporting industries in 2012 [11] and is expected to 

grow to more than $3.5B by 2017 [12] and to $10B by 2022 [13]. The AM material market is 

expected to grow from $470M in 2013 to over $1.09B in 2022 [13]. Industry, government and 

academia in the U.S. have been working to support the rate of growth by expanding machine 

capabilities and developing new high strength and biomedical materials. A report by IDTechEx 

as reported in The Guardian indicates the dental and medical market is expected to expand to 

$867M by 2025, the inclusion of additively manufactured organs and tissues would mean a 

potential of $6B within 10 years [14, 15]. 

Currently, there are few standards specifically addressing mechanical properties of AM parts. 

ASTM F42.01 has a number of standards and work items focused on metals AM [16]. There is 

currently one ASTM standard test method applicable to powder bed fusion of plastic materials;

F3091/F3019M-14 Standard Specification for Powder Bed Fusion of Plastic Materials [17]. The 

subcommittee has one work item that covers evaluation of manufacturing systems: WK 40419

New Test Methods for Performance evaluation of additive manufacturing systems through 

measurement of a manufactured test piece [18]. The International Standards Organization (ISO) 

has one active standard: ISO 17296-3:2014 Additive Manufacturing – General Principles—Part 

3: Main characteristics and corresponding test methods [19] to address quality characteristics of 

parts produced by AM. This standard references other ISO standards for mechanical property 

testing of polymers and metals, but there are no AM specific considerations in testing. The lack 

of AM specific mechanical standards creates challenges for stakeholders to provide equal 

comparisons between machines, materials, and models that predict final part properties in order 
3

to generate design allowables. Stahl has identified the inferior mechanical performance

compared to that for traditionally manufactured parts as a risk for AM [20]. 

2. Scope: 

The measurement challenges for AM, whether it is metal or polymer, are similar. Parallels 

between the material systems include: characterization of raw materials, development of design 

allowables, in-situ process and feedback control, workflow optimization, and modeling final 

properties [21]. The emerging engineering and standards challenges for high performance 

polymers and polymer composites are not directly addressed by the Engineering Laboratory 

Additive Manufacturing program, which is focused on metal applications. The scope of this 

report is to analyze the current trends in polymer additive manufacturing and determine the 

applicability of current ASTM and the ISO standard test methods for mechanical properties and 

failure of polymers and polymer composites generated from the additive manufacturing 

processes. 

This report follows the style of previous NIST Internal Reports (NISTIR), NISTIR 8005 [22] and 

NISTIR 7847 [23], from EL to document the standards needs in metal AM. This report will 

provide:

a. State of the art for additive manufacturing of polymers and polymer composites

b. Analysis of the technical hurdles that are preventing these materials from high 

performance manufacturing applications. 

c. Analysis of the current ASTM and ISO standards for measuring mechanical 

properties and failure of polymers and composites to include: 

i. Standard designation,

ii. Standard Name,

iii. Application to AM testing,

iv. Notes concerning each standard relevant to the AM,

d. Summary of recommended potential directions for NIST standards research in 

polymer additive manufacturing.

This report will also describe the emerging effort in the Material Measurement Laboratory

(MML) to support polymer additive manufacturing efforts and the potential opportunities for 

leveraging collaborative efforts between MML and the Engineering Laboratory. In order to limit 

the scope of this effort, concessions were made to focus on materials, measurement length scales, 

and types of standards as described below: 

• Polymers– Standardized methods for measuring the mechanical properties polymeric materials 

utilized in ME, laser sintering, and direct printing were addressed. Mechanical property 

measurement standards for polymer matrix fiber reinforced composites were also included for 

review. Fiber reinforced composites use a polymer matrix to support woven or aligned high 

strength fibers. Manufacturing composites requires stacking multiple layers of fibers and 

infusing the interstitial spacing with a polymer resin. The fibers are strong in the axial direction 
4

and weaker in the radial direction; the fibers provide anisotropy to the strength of the composite. 

Therefore, standardized measurements developed for mechanical properties in fiber reinforced 

composites may be applicable to additively manufactured materials. 

• Bulk Mechanical Properties – Standardized methods for bulk property measurements were 

addressed. Mechanical property measurements of localized properties, like those obtained by 

micro-indentation, hardness, and atomic force microscopy were excluded.

• Focus on International Standards – This was done in order to make the assessment practical. A 

cursory review of standards from the major Standards Development Organizations showed that 

ASTM and ISO mechanical testing standards are representative of all the pertinent standardized 

mechanical testing methods. A number of industry groups have developed protocols for 

reference tests. These tests are useful and some eventually become standards. Such tests are 

not covered here for three reasons: there are many such tests, often they are specific to an 

industry sector or product, and many are consensus methods that may lack the rigorous 

scientific basis and round-robin verification that is required for a standard. 

3. Government and Academic Support:

In 2009 the National Science Foundation (NSF) developed a Roadmap for Additive 

Manufacturing [24]. This roadmap addressed various challenges faced by the industry in the 

areas of design, materials, biomaterials, and energy and sustainability. The main 

recommendations from this roadmap were to:

 expand the capabilities of solid modeling to support additive manufacturing, 

 develop better closed loop and feedback control, 

 develop predictive process-structure-property relationships integrated into CAD/CAM 

tools, 

 improve physical models of AM processes to maximize the properties of AM parts,

develop and adopt internationally recognized standards which are useful to product, 

process, and material certification 

Chapter 6 of this report highlights the types of material properties that are measured to 

determine the engineering properties used to design structures. In addition, understanding the 

anisotropy of AM parts allows specific functionality to be built into the manufacturing process 

and this allows unique capabilities not achievable through other manufacturing methods. NSF 

funded additive manufacturing to a total of $200M from 1986 to 2012 [24].

In 2012 the creation of the National Network for Manufacturing Innovation (NNMI) was started 

by the Executive Office of the President to develop regional advanced manufacturing hubs [4].

One of the first hubs was AmericaMakes. AmericaMakes is a partnership among the 

Departments of Commerce, Defense, Energy, NASA, and NSF. This effort led to the funding of 

the National Center for Defense Manufacturing and Machining (NCDMM) in Youngstown Ohio, 

which brings together a regional network of 14 research universities, community colleges, 40 

industry partners, and 10 non-profit organizations spanning Western Pennsylvania, Eastern Ohio, 

and West Virginia. This effort is funded with a $40M private match to the initial $30M federal 
5

investment. NIST’s Measurement Science for Advanced Manufacturing program (MSAM) has 

funded NCDMM with $5M for research to ensure quality parts are produced from LS of metal 

powders [25]. The NCDMM mission is to build a national network for additive manufacturing 

and 3D printing technologies in the U.S. [5].

Currently, AmericaMakes is funding projects for ME processing of high-temperature 

commercial polymers, ME for complex shape composite tooling, and AM manufactured 

composite tooling for hydroforming. The University of Texas at El Paso has formed the 

W.M. Keck Center for 3D Evaluation which has one project to develop integrated technologies 

for multi-material structures [4]. In addition, materials characterization, quality control, data sets 

for process-property validation, and tailored materials have been identified as critical topic areas 

in both project calls from AmericaMakes.

Additive manufacturing has led to several centers of development within academia. The first 

freeform manufacturing center was started in 1988 at The University of Texas at Austin. 

Pennsylvania State University started the Center for Innovative Materials Processing through 

Direct Digital Deposition (CIMP-3D) for metallic AM with the following government partners: 

DARPA, ONR, and Battelle. This consortium is developing an advanced process modeling and 

analysis framework for metal manufacturing. This framework includes incorporation of material 

science principles (microstructure, kinetics, and thermodynamics) to predict and control the final 

properties of the additive manufactured part. The Consortium for Additive Manufacturing 

Materials (CAMM) was started in 2013 as part of the NIST AMTech program ($500K) and will 

develop a comprehensive roadmapping effort for new types of additive materials [26]. The 

American Lightweight Materials Innovation Institute is a partnership between the Edison 

Welding Institute, The Ohio State University, and the University of Michigan. The University of 

Connecticut has recently opened the Pratt & Whitney Additive Manufacturing Innovation Center 

to focus on metals. The Michigan Technological University hosts the Open Sustainability 

Technology Laboratory. This laboratory supports the development of open source software and 

hardware for all forms of additive manufacturing. The goal is to make additive manufacturing 

technology fully accessible to any user. North Carolina State University hosts the Center for 

Additive Manufacturing and Logistics. Northern Illinois University was awarded $2.4M through

the NIST MSAM program to develop physics-based AM models for process control and quality 

assurance [25]. Many of the academic efforts focus on the development of new materials, 

improvement of existing materials, development of instrumentation and test methods, and 

process material-property relationships for aerospace and biomedical applications. There is 

overlap within projects, but they are directed at improving the AM process and final products.

Additive manufacturing has recently been demonstrated for more than small parts and devices. 

Oak Ridge National Laboratory has partnered with Cincinnati Incorporated to develop a largescale polymer additive manufacturing system, with a goal of increasing speed by 500 times and 

building components that are 10 times larger (> 1 m3) than typical AM parts [27, 28]. Local 

Motors is a company that specializes in the development of large area additive manufacturing 

machines. This company additively manufactured an automobile during the International 

Manufacturing Technology Show within the exhibition hall [29]. They have recently opened an 

office in the National Harbor area of Washington D.C.; the large scale printer and polymers used 

for this demonstration were developed through collaborative research supported with ORNL. 
6

Andrey Rudenko additively manufactured a 2-story concrete home in the shape of a castle out of 

concrete [30]. While these applications remain a technical curiosity, they represent the desire to 

push the industry to stronger materials and applications critical to life safety.

One of the advantages of additive manufacturing is the accessibility of the technology to 

individuals, especially for soft materials. A large community of do-it-yourself consumers has 

grown up to provide open source plans for building machines, control software, start new small 

manufacturing businesses, and release of downloadable CAD drawings. The ease of technology 

transfer has spurned innovations in manufacturing at all levels. The growth of sub-$5K 

consumer-level printers is expected to increase [31]. Further information on advances in the open 

source additive manufacturing market may be found at RepRap project [32] and Makerspace 

[33] websites. 

The significant investment in AM from public-private partnerships, entrepreneurs, and the 

general public is expected to lead to new manufacturing technologies, better materials, and new 

markets for AM. Engineers require science-based standards to support design and validate 

mechanical performance. Machine manufacturers require methods to predict performance based 

on processing parameters (e.g. extrusion temperature, extrusion nozzle shape, extrusion velocity, 

etc.), which requires incorporation of polymer physics, constitutive equations, and improved 

process control methodologies. Standards will be critical to supporting competitiveness as these 

efforts mature to widely available manufactured products. 

4. Materials:

Polymers are critical for AM because they represent the greatest market penetration and user 

accessibility [31][32][33]. The importance of polymers to materials in this community has been 

documented through a survey of “commons based peer production” of users available through 

the web [34], where polymers represent the major source of printable materials. This was a 

survey conducted within the open source community, mentioned earlier, to gauge their materials 

and manufacturing needs. Figure 1 shows the breakdown of materials used in AM printing by 

tonnage used in 2013. Photopolymers generated over $239M in market revenue and the market is 

expected to reach $470M in 2022 [13]. Laser sintering equipment is not yet easily obtained by 

most non-manufacturing consumers because of the cost of the equipment and the difficulties in 

handling dispersible metal powders. Although polymers lag metals in the development of 

structural mechanical properties, the potential to impact many more markets from consumer 

products, sustainable applications, advanced manufacturing, and biomedical devices is far 

greater for polymers [15]. 
7

Figure 1: Pie chart showing the types of material utilized for AM as fraction of material 

consumed by AM from a user survey. [15]

There are a number of polymeric materials available from machine manufacturers and choices 

are dependent on the methodology used to create objects. A survey of websites from major 

equipment manufacturers, Statasys [35], 3D Systems [36], and Makerbot [37], reveal material 

choices that include acrylonitrile-styrene-butadiene (ABS), polycarbonate (PC), polylactide 

(PLA), toughened polystyrene, nylon, toughened polycarbonate, and polyurethane. Many of 

these materials are toughened to improve impact and fracture performance, but it is not clear 

whether AM takes full advantage of these properties. These materials are mainly employed for 

prototyping designs and the creation of low performance parts, but the demand for new higher 

performance polymer materials and composites is growing. 

There are several examples of advances in materials, machines, and control strategies to support 

these advances. Equipment manufacturers offer materials that perform at high temperatures, and 

are chemically resistant such as polyphenylene sulfide (PPS), polyetherimide (PEI), 

polyphenylsulfone (PPSU), and polyether ether ketone (PEEK). There are composites systems 

based on glass fibers, carbon fibers, and dispersed nanomaterials [38]. The car produced via 

material extrusion at the International Manufacturing Technology show utilized a discontinuous 

carbon fiber composite developed at ORNL through the DOE Manufacturing Demonstration 

Facility [39]. There are additional technologies to print both discontinuous and continuous 

carbon fiber composites [39, 40]. Arevo Labs has announced, through a press release, the 

capability to print multiple high performance polymers using a combination of Solvay polymers 

paired to advanced instrumentation control, with a claim to deliver parts designed to achieve 

predicted performance [41, 42]. The Army Research Laboratory (ARL) has demonstrated the 

capability to produce multi-functional composites using an electric Field-Aided Laminar 

Composite (FALCom) processing technique [43]. This process utilizes electric fields to align 

nano- and micro- particles into chain-like structures that are cured into place in the 

photopolymer. This increases strength and provides conductive pathways for multifunctional 

performance. Finally, a survey of recent meeting abstracts and industry press releases show the 
8

industry is moving towards printing multiple materials, colors, and functionality within the same 

part. This will increase the complexity in predicting the final properties of the object or system.

While the choices for materials and manufacturing processes continue to improve, the ability of

stakeholders to compare materials/machines for development of part design and performance has 

not followed a parallel path. Performance property information within the technical data sheets 

for these materials is not standardized. There are no defined standards to classify materials or

standardized processing/manufacturing parameters used to specify the properties of a final part. 

A search of the technical data sheets for materials used in additive manufacturing that includes 

fused deposition and direct printing materials provides an idea of the important mechanical 

properties and the standard tests used to specify those properties. The standards are ASTM D638 

(tensile strength, elongation at break, modulus of elasticity) [44], ASTM D790 (flexural strength, 

flexural modulus) [45], ASTM D256 (Izod Notched Impact) [46], and various hardness scales. 

According to ASTM D5592 [47], several of the above-referenced ASTM standards are 

applicable to the development of engineering design properties for load-bearing plastic 

components. These include ASTM D638 (tensile), ASTM D695 (compression) [48], ASTM 

D2990 (creep) [49], ASTM D3418 (transition temperatures for semi-crystalline polymers) [50], 

ASTM D4473 (dynamic mechanical for cure behavior) [51], D5045 (plane-strain fracture 

toughness) [52], ASTM D5279 (dynamic mechanical properties in torsion). ASTM D5592 [47]

was used to identify the ASTM standards typically used in engineering design of plastics for this 

survey.

While manufacturers provide some traceability to mechanical property testing, the information is 

not complete. For example, some manufacturers provide printing parameters and others provide

no printing parameters. The quality assurance provided on the raw materials prior to printing is 

not defined and polymers remain a black box. Manufacturers control their interactions with 

suppliers and the resins are tailored for their machines. Variability within molecular weight and 

distribution, dispersed phase volume concentration, viscosity, void content, crystallinity, range of 

additives and other performance qualities required for a specification are not reported. These 

materials are still fabricated for existing, conventional manufacturing processes such as 

compression or injection molding. The range of melt parameters, e.g. melt viscosity or melt 

index, for a commercial extrusion/injection process may not be compatible for the AM process 

and the lack of standardization has led to material disclaimers provided on technical datasheets, 

for example:

"The performance characteristics of these materials may vary according to 

application, operating conditions, or end use. Each user is responsible for 

determining that the Stratasys material is safe, lawful, and technically suitable 

for the intended application, as well as for identifying the proper disposal (or 

recycling) method consistent with applicable environmental laws and 

regulations. Stratasys makes no warranties of any kind, express or implied, 

including, but not limited to, the warranties of merchantability, fitness for a 

particular use, or warranty against patent infringement. The information 

presented in this document are typical values intended for reference and 

comparison purposes only. They should not be used for design specifications or 

quality control purposes. End-use material performance can be impacted (+/-) 
9

by, but not limited to, part design, end-use conditions, test conditions, color, etc. 

Actual values will vary with build conditions. Tested parts were built on Fortus 

400 mc @ 0.010” (0.254 mm) slice. Product specifications are subject to change 

without notice.”[35]

As will be demonstrated in the specific standards discussion below, process variables and 

manufacturing design can lead to final parts with anisotropic, inconsistent or substandard 

performance. 

5. Mechanical Properties for Design:

Accurate mechanical property measurements are required to select materials and design a 

structure for its intended application. Engineers utilize this knowledge to make material 

decisions in both safety-critical and non-safety critical designs. These properties are determined 

using accepted measurement standards, certified databases, or reference materials. Applicable

test standards are determined based on the final usage of the material, inherent weakness in the 

design, durability requirements, and safety factors. The Department of Defense Composite 

Materials Handbook has a useful reference that illustrates the staged process of a “building block 

approach” for determining the properties of the material and transitioning that information to the 

performance of the system [53]. Figure 2 shows the building block approach utilized to minimize 

the risk of new material insertion into aerospace structural systems. The building blocks to safely 

incorporate new materials into structural design rely on increasing the scale of testing from 

coupon tests to more complex component tests and finally full scale tests. This approach will be 

used to illustrate where standards for mechanical property measurements of AM manufactured 

parts are needed to incorporate new materials or designs into systems. 

The parameters that define the system are collected within the design considerations (lower 

block, purple in figure). Engineers require estimates of the loading, temperature, moisture 

environment of the application, and material information such as mechanical properties, long 

term stability, susceptibility to damage, and manufacturing cost prior to designing a part. Design 

considerations for AM follow the same requirements as any other manufacturing process. 

Supporting technologies (left block, yellow in figure) are the technologies to obtain, measure, and 

validate the material information. In AM, this can be difficult because material property 

information is often controlled by manufacturers and dependent on AM processing. The engineer 

must decide how material properties will be validated through standard test methods, how 

statistical analysis will be done to determine the properties of the population, estimate the needs 

for post-processing of the part, and determine whether non-destructive techniques are required to 

validate internal structural dimensions. If these properties are dependent on material source and 

machine manufacturer such as in AM, it becomes difficult to estimate the level of Supporting 

Technologies required. The Building Blocks bring all of these considerations together (center 

block, green in figure). The building blocks allow engineers to understand material performance, 

joining or bonding performance, performance of components working together, and finally full 

incorporation into a full scale system test. In AM this may require significant effort for coupon 

level tests such as printing a single bead of material to optimize extrusion parameters, moving to 

ASTM dog bone geometries to identify optimal print layouts and finally incorporating the AM 

part into the other elements and components for further testing. In today’s modeling intensive 
10

world, many of these concepts are validated via simulation. Therefore, science-based 

standardized testing is required for AM materials to support accurate simulations. This testing 

requires confidence in material mechanical properties and performance, which is an area that 

AM is lacking.

Figure 2: Building block integration for the development of composite structures [53].

The building block integration approach (Figure 2) may be further expanded to highlight the type 

of information gathered from each of the building blocks. Figure 3 shows the building block 

approach for a commercial aircraft composite primary structure to provide an estimate of the 

level of experimental effort anticipated at each stage of the building block. The use of aggressive 

environments (Environment) allows engineers to scale allowed loading or strain limits for the 

material based on the effects of temperature, moisture, or cycling. Coupon level testing relies on 

simplified sample and test geometries that deliver specific information such as mechanical 

properties (modulus, strength, etc.), interlaminar properties, adhesive properties, and durability 

(highlighted Coupons and Elements). These tests may easily number in the thousands to build 

statistical confidence in performance. Success beyond the coupon level leads to manufacturing 

smaller structures with increasing complexity for assembly (inclusion of joints and bolts) and 

loading (stress concentrations, off-axis loading). The costs per subcomponent increase, therefore,

sampling is smaller. The coupon level and element level require a firm understanding of the 

impact of manufacturing processes on performance, and demand a science-based standardized 

testing framework to increase success in the final subcomponent stage. For any processes, 

weaknesses must be identified at this time to prevent costly engineering choices in the final 

structure and before manufacture and testing of large panels or subcomponents. An additive 

part will readily cross between the coupon and element level because performance may be 

defined by internal fusion joints, print directions, manufacturer, additive method, and material 

supplier. Large panels permit the validation of the design concepts and analysis methods are 
11

fully validated. Failure or success of the structure can validate the material design values 

developed from earlier testing. Each level of testing is used to support structure performance 

models to reduce test costs, but models rely on accurate material and interface property 

measurements. Accurate material and interface property measurements rely on a solid 

framework. 

Figure 3: Building block approach for the support of composites structures in the 777 aircraft 

[53]. In this graphic durability is defined through moisture stability, temperature stability, creep 

resistance, and fatigue resistance.

From the stratified view of the building block manufacturing or qualification approach, there are 

identifiable challenges for AM. The first challenge is the identification of test methods for 

characterizing the mesostructure of the AM part at both the structural level and the molecular 

level. The mesostructure is defined at the structural level by anisotropy in the axial direction of 

extruded material, the presence of voids, and the degree of curing between reacted or melted 

layers during the deposition process. Many AM systems allow for complete infill (no voids) for 

ME and voids may not be as prolific in sintering, this does not eliminate anisotropy in 

mechanical performance. The mesostructure at the molecular level is defined by the degree of 

mixing between polymers with differing thermal histories, degrees of dispersion in composites, 

the coefficient of thermal expansion mismatches, and the adhesion between dissimilar materials. 

Both length scales lead to anisotropy in performance. Figure 4 is a cross-section of an ME 

produced part that highlights the potential mesostructure present from incomplete bonding 

between lines of extruded material. The majority of literature concerning material extrusion

processes addresses the impact of different void space between lines of extruded material, 
12

orientation of beads to load direction, and the influence of build direction. The current focus for 

this overview will be the combination of material direction and void space that leads to the 

structural level mesostructure. These types of porous structures represent a significant challenge 

for engineers to determine safe design parameters. Engineers need to understand the strength of 

the fusion, strength of the bead, and the micromechanics of a porous structure. Standards 

provide the framework of scientifically grounded test geometries and methodologies to address 

the challenges of AM and facilitate a smooth transition between boxes to produce design 

parameters.

Figure 4: Mesostructure of an ME-ABS material illustrating the porous structure that may be 

achieved based on the raster angle and bead overlap [54].

Given the complicated mesostructure of AM parts, the scope of this standard review was 

expanded to include standard tests used for fiber composite materials. Fiber composites are 

lightweight structural materials that contain high strength fibers (E~70 GPa to 250 GPa) 

embedded in a polymer matrix material (E~ 3 GPa to 4 GPa). The fibers carry any significant 

loads and the matrix is designed to provide rigidity to the fiber structure. Since the fibers are 

stronger in the axial direction, the resulting composites can have significantly anisotropic 

properties. This anisotropy has been addressed in standards by specifying the directionality of the 

fibers. Figure 5 shows an example of fibers oriented in different x,y directions along the z-plane. 

If this rotation is done symmetrically, the composite laminate may be considered quasi-isotropic

in material properties in the plane of the fibers. While geometry guidelines are critical for fiber 

composites, it is not clear whether these are valid for AM materials since stress distribution 

through the AM mesostructure will differ greatly from a fiber composite.
13

Figure 5: Graphic illustrating the directionality of fibers, through z, in a fiber composite 

laminate. The orientation and number of fibers controls the performance of the composite.

Mechanical properties: These properties are often defined in terms of the behavior at loads that 

do not produce failure or failure behavior itself. For solids, the first case is generally 

characterized by moduli that are defined as the stress divided by the strain. Moduli can be 

measured with a number of different loading modes: tension, compression, flexure, shear, or 

torsion [55], and in the linear region, they are proportionality constants independent of strain. 

The moduli of polymeric materials are functions of temperature and time. These dependencies, 

particularly temperature, are important. For many polymers used in additive manufacturing, 

these properties are often reported in the technical specification sheet in tension (or compression) 

and shear loading modes. Since two parameters are needed to model behavior in different 

loading directions, an alternative is to report Young’s Modulus and Poisson’s Ratio. Poisson’s 

Ratio is the negative ratio of transverse to axial strain.

Failure Properties: As the stress increases, materials begin to fail via plastic deformation (nonlinear stress vs. strain) or brittle fracture. One approach to quantify failure behavior is by 

determining yield strength, ultimate strength, and impact strength. Each one of these may be 

defined in relationship to the mode of loading: tension, compression, flexure, shear, or torsion 

[55]. For many polymers used in additive manufacturing, these properties are often reported in 

the technical specification sheet in tension or compression loading modes. On the other hand, 

these parameters do not adequately characterize materials that fail by the propagation of cracks. 

To describe this behavior requires fracture parameters that are often not reported in the technical 

sheet [53]. The fracture toughness or fracture energy of the material is [55] defined in three 

modes (I: crack opening, II: in-plane shear, and III: out of plane shear) as shown in Figure 6.

Standards are available to test in Mode I, Mode II, and mixtures of Mode I and II, although the 

complex shapes of many AM parts may increase the importance of Mode III. Fracture toughness 

is a critical factor for ME and LS created polymer parts and given the complex mesostructure 

and anisotropy, it may be difficult to induce purely one loading Mode for testing.
14

Figure 6: Three modes of crack surface displacements Mode I (opening or tensile mode), Mode 

II (sliding mode), and Mode III (tearing mode) copied from [56].

The terms used to define failure properties are given below: 

Yield Stress/Yield Strength

Ultimate Strength

Elongation at Yield

Elongation at Break

Fracture Toughness

Fracture Energy

Impact Strength

Bearing Strength

Open Hole Compression Strength

Crack Growth Resistance Curves

Bearing and open hole tests evaluate the ability of the material to perform with an engineered 

flaw such as a bolt or pin in the structure.

Interlaminar properties are important for fiber reinforced composites. As shown in Figure 5, the 

fibers lie in a plane and provide high strength and stiffness in that direction. Although designers

plan structures so the loads are in the fiber direction, unexpected events can produce loads 

perpendicular to this plane, which causes damage. This can significantly reduce the performance 

in the fiber direction, particularly compressive strength. Often the fiber-matrix interface 

represents the weak point of the composite because it relies on bonding between the fiber filler 

and the compliant matrix. Interlaminar test methods allow the user to understand the 

susceptibility of the material to damage between fiber layers. Unfortunately, interlaminar 

properties do not provide explicit engineering limits on the maximum load that a composite 

material can bear in off-axis loading, but tests like interlaminar fracture and short beam strength 
15

can indicate general ranking. For composites, standard test methods for interlaminar properties 

are:

Short beam strength

Shear modulus

Ultimate shear stress strength

Durability: Durable material properties may be quantified using several standards depending on 

the usage of the material. In the context of this review, durability is addressed for mechanical 

durability, specifically creep and fatigue. There are standards available in ASTM and ISO that 

define exposure conditions for moisture, temperature, and artificial sunlight exposure on 

materials. Creep is important for understanding the ability of the material to withstand long-term 

static loading. Fatigue properties are important for understanding the ability of the material to 

withstand cycling loading during usage. Finally, impact strength is a measure of the material to 

withstand high strain rate loading and evaluate the ability of the material to absorb energy and 

resist damage. Mechanical properties that define mechanical durability are: 

Creep Modulus

Creep Rupture

Fatigue life (S-N plots/R-N plots)

Standards are important for mechanical and failure properties because they are the language that 

mitigates risk within the design and allows engineers to build structural and safety critical parts 

with a known performance window. The specific ASTM and ISO standards that are applicable to 

quantify the material properties listed above will be addressed individually.

6. Challenges for Mechanical Property Characterization:

While AM provides the opportunity to quickly go from design to product especially for parts that 

have difficult or impossible to machine features, challenges remain for predicting mechanical 

performance. Many AM processes differ from traditional polymer processing in that not all of 

the material is melted and homogenized. The AM process of depositing layers of polymeric 

material results in parts with anisotropic properties, residual stress, and this is a significant 

challenge. Researchers and Original Equipment Manufacturers (OEMs) must establish the 

standardized methods to determine material properties from AM processing rather than the 

mechanical properties of a particular design. Peer-reviewed literature has begun to highlight 

complexity in relating material properties, AM mesostructure, and part design for standardized 

testing. Despite the importance of this problem for the success of AM as a critical manufacturing 

process, the literature available in this area is not significantly large. Figure 7 shows the typical 

geometrical variables related to ME deposition geometry. 
16

Figure 7: Graphical representation of process variables related to the build geometry for additive 

manufacturing. a) raster angle, b) extruded filament height and layer width, c) air gap between 

extruded filaments, d) combinations of variables (T, air gap, width, height, velocity) can increase 

the coalescence between filaments, e) the build direction can affect the load transfer between 

filaments and interfaces.

The majority of studies have focused on the impact of raster angle, air gap, filament width, layer 

height, and build orientation to major part axis (i.e. x, y, or z-direction). Build orientation allows 

one to capture interacting factors such as filament length, temperature gradients, and nozzle 

velocity on mechanical properties. Many additive systems that rely on material extrusion 

processes allow for full infill of the deposited part, but it was not possible to compare literature 

studies directly. Evidence for mechanical anisotropy was more readily identified in the literature 

for powder bed fusion processes.

The impact of processing for anisotropic mechanical properties in material extrusion 

has been identified by multiple authors with ME processing of ABS polymers as a major focus

[54, 57-68]. In the case of ME, AM parts exhibit inferior mechanical properties compared to the 

as-received polymer filament that feeds the AM extruder head and compression molding or 

injection molded parts constructed from this same as-received filament. Raster angle is a process 

parameter that influences anisotropy and strength in AM parts. Rodriquez showed reductions in 

modulus can range from 11 % to 37 % [65]. In general, parts were stronger when the beads were

aligned in the loading direction for tensile loading [57, 64], mixed angles for flexure [57, 58], 

and orthogonal to loading for compression [67]. Ahn used twelve layers of ABS oriented in 

[0 o], [45 o /- 45 o ], [0o /90 o ] and [90 o ] to investigate the effect of raster angle [57]. Alignment 

of long fibers with the loading path increased strength, but gaps between bead layers reduced 

strength. Similar work in unidirectional deposition of materials supports this idea. Es-Said found 

that increasing raster angle lowered strength, but had little effect on modulus [59]. They also 
17

found that failure tended to occur in the deposition lines. As the raster angle increases the tensile 

properties of the material are reduced [57, 65]. Huang has shown that tensile and shear properties 

of unidirectional ABS parts reach a minimum around raster angles of 50o [61]. Similar results 

have been found for ME production of PC materials. Masood could achieve approximately 80% 

of an injected molded material by aligning the beads with loading [63]. Hill conducted a 

systematic study of raster angle on unidirectional parts with similar density and found that 

aligning the beads in the axial direction produced the best failure properties [60]. The strength 

could be modeled using micromechanics to account for the fusion strength.

The air gap influences void percentage, which plays a large role in determining mechanical 

properties. The strength of the AM part is not only derived from lines of extruded filament, but 

the interaction between filaments is important. The presence of voids and sharp corners increase 

stress within the part and failure can initiate at these features [58]. In general, minimizing the gap 

between filaments increases the contact area between filaments and leads to a stronger fusion 

interface. Rodriguez has shown that a combination of process parameters may be used to control 

the void space, and he could model the resulting structure using laminate theory [65]. ME relies 

on the thermal gradients between neighboring filaments to allow the thermoplastic polymers to 

diffuse and form a stronger fusion interface. These fusions have been compared to the matrix in a 

fiber reinforced composites because they hold the filaments together [65]. The time required to 

maximize bond strength between successive filaments is not immediately known from technical 

data sheets, but it is related to the structure of the polymer (molecular weight, glass transition 

temperature, crystallinity, etc.) and the thermal gradient between the new filament and the 

previous filaments. A guideline was developed to minimize the air gap and optimize the bead 

width or height to increase contact area in order to improve bond strength. Sun observed 

temperature profiles in ME and bead interface formation to quantify interface formation. He

found that envelope temperature and convection in the build chamber have a significant effect on 

mesostructure [69]. Sood et al. used a response surface developed from design of experiments 

coupled to neural network analysis to demonstrate the non-linear behavior of printing parameters 

and utilized neural network modelling to predict compressive properties [67, 70]. Another 

empirical study led to six build rules to help designers maximize mechanical performance [57].

These studies have highlighted the complicated relationship between the build parameters, part 

design, and final properties.

There are examples of unintended consequences from not accounting for interacting parameters. 

Decreasing the bead width reduces residual stress in the filament and can increase diffusion

length, but requires more laps to create the part. Residual stress is caused by the contraction of 

the polymer filament on cooling. In the case of semi-crystalline materials, the contraction of 

volume from crystallization increases residual stress at interfaces. In order to fill the space with a 

smaller filament width, the nozzle must complete a higher number of long passes and short 

passes for direction reversal. The extruding nozzle will change speed to accommodate the 

printing process; the corollary for sintering is laser raster speed and energy. The successive 

thermal cycling caused by changes in nozzle speed impacts thermal diffusion because speed 

changes impact residence time [70]. Another example is maximizing the temperature and 

filament height can lead to part distortion and surface roughness that negatively impacts 

appearance and mechanical properties. Orientation of the polymer during extrusion will reduce 

strain to failure up to 33 % [58] and increase the time for polymer diffusion, but orientation has 
18

not been sufficiently addressed in the literature. Failure in these materials is often brittle and 

driven by build construction. Larger filament widths, oriented polymer within beads, and poor 

diffusion are all suspected to lead to inter-laminar failures facilitated by defects and surface 

roughness at the fusion lines. These factors need to be accounted for in models, validated 

through standardized testing, and incorporated into the process workflow to support AM.

It is difficult to isolate the impact of build direction on anisotropy because this is often 

confounded with other build parameters. Riddick et al. combined xz, yz, and xy build directions 

with changes in bead length and raster angle combinations of [0 o], [0o /90 o] and [90 o ] and

found that the xz direction had the highest modulus (2.67 GPa) and strength (15.26 MPa) due to 

a combination of void filling and optimal raster geometry [64]. Others have found that build 

paths that maximize alignment of fibers in the loading direction increased strength [58]. There 

are a small number of studies investigating the durability of ME parts. One study showed that a 

PEI/PC blend aged at room temperature and water was stable over 52 weeks and relatively 

insensitive to short time exposure to aerospace solvents [71].

Similar challenges exist for powder bed fusion processing and concern the impact of thermal 

gradients and void space in the part. If the layer heights are too large, the powder acts as a 

thermal insulator which prevents heat transfer to the lower powder layer. This can reduce the 

consolidation of molten material into the gaps below and inter-diffusion of polymer species [7].

The crystallization temperature of the material is important for the increase of bonding between 

the molten beads [72]. Shrinkage has been shown to depend on different build parameters based 

on laser raster direction, where laser power and scan length are critical for x-direction while

hatch spacing and part bed temperature are critical for the z-direction [73]. Recycled powder 

presents a challenge for laser sintering. There is potential for polymer aging and crosslinking for 

a material that has been previously processed, but not sintered. This aging increases melt 

viscosity and prevents flow, which creates weak interfaces and defects within the part. Thermal 

control of the powder bed is also important. Improper powder bed temperature leads to 

interruption of the thermal gradients during the sintering process which can lead to reduction in 

performance [72]. Leigh found that increasing the size of the polymer interface, characterized 

by an h/r ratio (see Figure 6b and 6d) increased the yield stress and ultimate tensile strength [7],

but there was limited information found on durability studies for LS parts. One study showed 

that these materials exhibited a slight drop in mechanical properties when subjected to aggressive 

automotive fluids, similar to the performance of the base polymers [74].

In the case of material jetting, the kinetics of the photo-polymerization reaction and thermal 

annealing of the part must lead to uniform cross-linking between successive layers. Lee found 

that 3D printing produces anisotropic materials with much lower compressive strength [62]. 

Additional challenges include the presence of additives, printing on an over-cured surface, and 

the proprietary knowledge of formulations. Similar to thermoplastic technologies, the print resin 

formulations are not known to users. Therefore, the impact of reactants, catalysts, and monomer 

molecular weight are difficult to separate. The photochemistry literature of dental resins, 

photolithographic patterning, and radiation curing is expected to contain a wealth of prior art 

concerning optimization of formulations and processing. A nanocomposite deposition system 

that produced composite parts, but requires a machining step after successive layers had 

mechanical performance closer to ME produced parts, although the materials remained 
19

anisotropic. Ang et al investigated the impact of trapped volume (voids) and trapped material for 

various rapid prototyping metrologies [10]. They found that these artifacts affect the 

functionality and dimensional stability of the final part, but they did not measure the mechanical 

properties.

Research is moving towards a better understanding of raw material microstructure, the physics 

and chemistry of polymer fusion and photopolymerization, and utilizing composite modeling to 

understand anisotropic properties as a function of the AM mesostructure. Fusion and coalescence 

have been presented in terms of a Frenkel-Eshelby formulation [61]. Huang was able to combine 

a force model with an understanding of the magnitude of coalescence to predict the performance 

of ABS. Composite models have been used to understand the deformation of these materials with 

an eye toward design variables and identifying fusion contributions to properties [58, 60, 65]. 

Many of these studies have been done on industrial or consumer-grade equipment [68], and it is 

not clear how the structure of the raw materials and tolerances of the process variables were 

controlled. There is much work that is required to drive current research towards industrially 

relevant AM standards.

7. Overview of Standard Testing Methods

There are two standards groups addressing AM. In ASTM committee F42 has jurisdiction over 

Additive Manufacturing Technologies and subcommittee F42.05 addresses materials and 

processes specifically [75]. TC 261 promulgates standards in the AM fields for the ISO. Both of 

the groups currently address mechanical testing of AM materials and parts via reference to 

established standards [76]. The following analysis describes the applicability of existing 

standards to mechanical testing of polymer AM materials and parts. 

7.1. Tension

These standards are classified for plastics (ASTM D638 [44], ISO 527-2 [77]) and composites 

(ASTM D3039 [78], ISO 527-4 [79, 80]). The standards utilize dog-bone or end tab specimens 

whose geometry is based on the thickness of the sample or the type of composite. Tension 

measurements provide Young’s modulus, Poisson’s ratio, Yield Stress, Strength, and Elongation 

to Break. The standards for composites address the orientation of fibers within a composite, but 

the applicability of such standards to AM materials has not been thoroughly described in the 

literature. Ahn found that the ASTM D638 type I sample geometry caused premature failure of 

specimens. Early failure was caused by a stress concentration within the radius of the dog bone 

near the gauge length. This area of specimens contained the ends of filaments, which caused 

excessive shear. The authors switched to the ASTM D3039 geometry to alleviate the problem. 

However, this was the only reference found with this problem. ISO 458 [81], which was not 

reviewed, provides the test standard for the stiffness of a material under torsion.

7.2. Flexure

ASTM D790 [45] and ISO 178 [82] are equivalent standards that utilize a three-point bend 

method to measure the flexural modulus, flexural strength, flexural stress and strain at break 

within a 5 % strain limit. If the strain limit is not met, then ASTM D6272 [83], which is a four-
20

point method, is used to increase the chance of achieving a failure measurement. This test 

reduces the stress concentration associated with the center roller in a three point test. These 

standards are applicable for unreinforced and reinforced materials. For composites containing 

high modulus fibers, ASTM D7264 [84] should be used for testing. The standard does not 

address the specific challenges for AM materials that may have anisotropic properties.

7.3. Compression

The applicable standards for compression measurements are ASTM D695 [48] and ISO 604 [85]. 

ASTM D3410 [86] and ISO 14126 [87] are specific to compression of a fiber reinforced 

composite in-plane direction. The standards provide measurement of compressive modulus, 

compressive yield stress, compressive strength at failure, and compressive strain at failure. There 

are geometrical restrictions for the diameter and height of the sample. 

7.4. Shear

There are a number of different standard tests to measure the shear modulus and strength of 

materials. The fiber reinforced composite standards (ISO 14129 [88], ISO 14130 [89], 

ASTM D2344 [90], and ASTM D3518 [91]) are not directly applicable to AM. These methods 

are developed for polymers reinforced with high strength fibers or textiles in specific orientations 

to the loading direction. The standards require determination of specific interlaminar failure 

modes between the aligned fibers. These types of samples are not typically manufactured in AM. 

There are also two notched specimen standards ASTM D7078 [92] and ASTM D3846 [93] for 

measuring shear properties. These standards utilize specimens with specific notch geometries 

and defined alignment of the fiber reinforcement. These test methods may not be directly 

applicable to AM manufactured materials for two reasons. First, AM produced parts do not 

possess the large ratio of moduli and failure strength in different directions that is found in fiber 

composites, therefore the mechanics of load distribution and crack propagation will be different 

in an AM material. Second, composite laminates may be manufactured with sharp initiation 

cracks in the matrix between the fiber layers. These cracks increase the precision of the test used 

to measure a material failure property. The current thermal processing methods in AM are not 

conducive to intentionally producing a well-defined, sharp initiation crack, and this will hinder 

the ability to characterize failure behavior. There are methods to introduce a sharp crack into a 

material. Fatigue, which is used for metals, does not work for polymeric materials, and the use 

of a sharp edge, such as razor blades, may not produce a proper crack in AM parts. 

There are only two shear standards that are directly applicable to AM. These are ASTM D4255

[94] and ISO 15310 [95] to determine the shear modulus of plastics and fiber reinforced 

materials, respectively. These standards allow for testing isotropic materials, but there is no 

guidance for testing materials constructed via AM. 

7.5. Creep

Creep measurement standards provide the methodology to measure dimensional changes in 

samples under load as a function of different exposure environments such as temperature, 

aqueous, or surfactant solutions. There are a variety of loading environments: tensile, 

compression, flexure, and solutions. ASTM D2990-09 [49] references ASTM D543 Practices for 
21

evaluating the resistance of plastics to chemical reagents for testing in environmental conditions

[96] that specifies solution composition for sample immersion. The ISO standard equivalent is 

ISO 899 [97, 98]. There are restrictions on the ratio of the length to the cross-section. The 

method recommends testing at a minimum of two different test temperatures within the use range 

of the material to understand the effect of temperature. Loading at seven stress levels to produce 

creep-rupture at different times up to 3000 h provides a measure of long term performance. 

Design data for creep is obtained by testing materials at different stress levels to produce 1 % 

strain in 1000 h. There is no guidance provided for anisotropic samples, such as fiber 

composites. 

7.6. Fatigue

ASTM D7774 [99] is the standard for uniaxial loading with no equivalent in ISO. The test 

frequency can range between (1-25) Hz, but less than 5 Hz is recommended. This frequency

reduce the chances of heat generation in the sample. The test method allows generation of a 

stress or strain as a function of cycles, with the fatigue limit characterized by failure of the 

specimen or reaching 107cycles. The 107cycle value is chosen to limit the test time, but 

depending on the applications this may or may not be the best choice. The maximum and

minimum stress or strain levels are defined through an R ratio. The R ratio is the ratio of 

minimum to maximum stress or displacement that the material is cycled through during testing. 

Testing is conducted within the elastic limit of the material. For this standard, samples may be 

loaded in either tension or compression.

ASTM D7791 [100] and ISO 13003 [101] are the test methods for flexure fatigue of plastics. 

The subject matter of the tests is similar, but technically different. In both tests, the loading is 

sinusoidal. ASTM D7791 utilizes either a three-point or four-point loading with cycling 

occurring in positive and negative directions. Control occurs in either stress or strain versus cycle 

number. The R ratio is -1 and the stress or strains do not exceed the proportional limit. The test 

ends at either failure or reaching 107cycles. 

ISO 13003 calculates the ultimate tensile/flexural strength for fatigue loading rate. In strain 

control, the end of the test is listed as the damage level related to specimen stiffness reduction of 

20 %. Four fatigue levels are tested in accordance with the fatigue life of interest or the range of 

stress/strain of interest. Similarly, strain or stress vs. the number of cycles is reported. Neither 

standard addressed the challenges associated with AM processing inducing anisotropy within the 

materials.

There are two standards that relate to fatigue delamination or crack propagation. These are 

ISO 15850 [102] and ASTM D6115 [103]. Both of these standards are specifically applicable to 

the measurement of fracture energy in the interlaminar region of a fiber composite. Similar to 

other composite specific standards, it is not clear whether AM materials would meet the fracture 

mechanics assumptions that support these standards. 

7.7. Fracture Toughness

Fracture toughness measurements are used to determine the energy required to initiate crack 

propagation from a precrack within a material or composite. These values are used for designing 
22

parts and developing materials. These standards often require the development of a sharp precrack within a material, application of load, and monitoring of the load, displacement, and crack 

progression. A linear elastic fracture mechanics analysis was used to develop measurements of

fracture energy (GiC) and fracture toughness (KiC), where i indicates the mode of loading I, II, or 

III, see Figure 6. In composites, these measurements are used to determine the fracture toughness 

between plies containing high modulus fibers or textiles. In polymers, this test provides material 

properties for engineering design. These often require the insertion of a pre-crack material to 

create the sharp crack, which may be problematic given the dimensional limitations for AM 

processes. 

ISO 15024 [104] and ASTM D5528 [105] are specifically for fiber reinforced composites. These 

standards are used to generate crack growth resistance curves (R-curves), which are measures of 

delamination resistance through the composite. They are not directly applicable to current AM 

manufacturing because continuous fibers are not present. It is not immediately clear whether 

these concepts could work for evaluation of the mesostructure or fusion zone in an AM material. 

ISO 29221 [106] is a standard for the plane-strain crack-arrest toughness in a compact tension 

specimen. This requires a sharp initial crack and a groove in the sample to limit the location of 

crack growth across the specimen. The challenges in AM relate to the dimensional resolution of 

the AM process and whether the impact of build direction on the propagation of the crack.

ISO 13586 [107] applies to the measurement of rigid and semi-rigid thermoplastics and 

discontinuous fiber composites. The biggest question is the influence of the mesostructure 

created during the AM process to measure a material property. An amendment to ISO 

13586 [108] provides testing injected molded composites with directions for testing longitudinal 

and transverse processing directions. This would be an acceptable place to start for determining 

the applicability of this test standard to AM parts. 

ASTM D6068 [109] is for the development of J-R curves for plastic materials. This is a specific 

method to develop an understanding of parameters for cohesive zone modeling of crack 

propagation. The method requires optical measurement of crack growth. This method may be 

applicable to specific types of deposition processes such as powder bed fusion of clear 

thermoplastics or material jetting of clear photopolymers, but it would still require the machining 

of a crack into the sample. 

7.8. Impact

ISO 179 [110, 111] and ASTM D6110 [112] describe the method for the Charpy impact test. ISO 

180 [113] and ASTM D256 [46] are the methods for Izod impact testing. Impact testing is 

mentioned with technical data sheets for many AM relevant polymers. It is not clear how the AM 

material is prepared and oriented for impact testing from the material data sheets. The main 

differences between the tests are the material position and notch placement. The load is applied 

rapidly by hitting the sample with a heavy striker. In the Izod test, the material is in a vertical 

position and the notch faces the striker. In the Charpy test, the material is horizontal with the 

notch away from the striker. The Charpy notch may be a V or a U-shaped notch. Similar to 

fracture toughness testing, it is not clear whether the notch may be sufficiently deposited into the 

AM part or should be machined at a later date.
23

7.9. Bearing Strength and Open Hole Compression

These tests represent functional strength tests for composites that will be fastened using bolts. It 

can also provide some insight into the effects of a damage region on performance. The specific 

standards are ASTM D953-10 [114], ASTM D5961 [115], and ASTM D6484 [116]. In ISO, the 

specific standards are ISO 12815 [117] and ISO 12817 [118]. The tests develop design 

parameters for integrating composites materials together and within structures. Currently, no 

demand was observed in the literature for these types of measurement standards by the AM 

community, which is not to say the demand does not exist. It is feasible that as AM materials are 

integrated with other structures such as in the human body, the community will need to 

understand the impact of part design on load carrying capability and whether the part will deform 

over time. Current standards should be directly applicable, but there should be comments 

provided on material isotropy.

8. Standards Applicability Assessment

In the following charts, ASTM and ISO standards were evaluated to determine their applicability 

to additive manufacturing. One of three classifications is given for each standard. If special 

consideration should be noted for the standard, specific notes are provided. The list covers 

standards for plastic materials and composites. The following labels are used for assessing 

applicability of the standard:

• YES – The standard should be applicable for additive manufacturing with very minimal 

or no modifications. 

• YES WITH GUIDANCE – The standard should be generally applicable for additive 

manufacturing, but there may be limits on its applicability, and some modifications or 

additional considerations are probably needed. These include:

o Geometrical limits on test specimens

o Required post-processing such that specimens built via additive manufacturing 

meet the requirements of the standard; this typically includes surface finish, 

dimensional requirements, or pre-crack requirements. 

o Material isotropy requirements. AM specimens often have inherent anisotropy. 

The measurement methods that specify applicability for isotropic materials may 

still work, but the measured results may have larger uncertainties. This includes 

consideration of separating material properties from part properties.

o Application specific considerations, such as elevated testing temperatures or 

immersion environments.

• NO – The standard requires specimens that cannot be built via AM, even major 

modifications may not be adequate, another method is better suited for the measurement

or the measurement simply is not applicable. 

In some cases standards were identified and listed in the applicability index, but they were not 

specifically reviewed.
24
25
26
27
28
29
30
31
32

9. Polymer Additive Manufacturing at NIST

An emerging program for polymer AM started in MML in 2014. This program is not a

component of the current EL additive manufacturing effort focused on metal AM, but the two 

laboratory efforts are collaborating to leverage expertise. As mentioned earlier, thermal fusion is 

a critical component to the strength of AM parts. Maximizing adhesion across the fusion zone 

requires a balance between diffusion time, residual stress, and maintaining dimensional stability. 

There are 9 projects addressing challenges in metal and polymer AM. The polymer centric 

projects are shown below:

FY2015 Projects Division Project Leader (s)

Polymer Focus:

Mechanical Strength of Additive Manufactured 

Polymeric Materials

647 Jason Killgore

Interfaces and Bonding During Additive Manufacturing 

of Polymeric Materials

642 Kalman Migler; 

Kathryn Beers

Metrology of Defects and Distortion at Interfaces in 

Additive Manufactured Polymeric Materials

642 Kalman Migler; 

Ronald Jones

Metrology of Non-metallic Precursors and Relationships 

to Final Product Quality and Performance

643 Greg Gillen; Michael 

Verkouteran

Nanomechanical Property Measurement of Surfaces and 

Interfaces for Polymeric and Metal Additive 

Manufacturing Materials

643 Richard Gates

For material extrusion AM processes, the focus is on the interfaces of the deposition line and 

developing molecular level measurements to determine microstructure-processing relationships

within this fusion zone. These projects utilize AM process variables such as temperature, speed, 

and extruded filament size to maximize the width of the diffusion zone between model polymer 

materials. Polymer structure (chain-length, branching, chemistry) is systematically varied along 

with process variables. The diffusion zone is directly measured using spectroscopic rheology and 

neutron reflectivity to determine width, orientation, degree of entanglement, and mechanical 

properties. The neutron reflectivity studies will be jointly supported through the Additive 

Manufactured Polymeric Materials project led by Dr. Ronald Jones. Experimental results will be 

used to generate constitutive models for fusion bond strength and process parameters in 

collaboration with Georgetown University. The Mechanical Strength of Additive Manufactured 

Polymeric Materials project is led by Dr. Jason Killgore. Dr. Killgore is utilizing sophisticated 

elastic and viscoelastic measurements based on scanning probe microscopy and frequency shifts 

during contact with a material to determine mechanical properties through the fusion line. Future

efforts in this project will develop localized adhesion measurements for assessing the strength of 

the fusion line and potential defects caused by processing parameters. Dr. Richard Gates is 

utilizing a different set of nanomechanical measurement tools to investigate the mechanical 

properties of the polymer fusion interfaces. The final project is led by Dr. Greg Gillen and Dr. 

Michael Verkouteran titled Metrology of Non-metallic Precursors and Relationships to Final 

Product Quality and Performance. This project investigates the impact of resin properties on the 

final product properties for material jetting processes. In addition, the impact of photopolymer 
33

precursor structure and formulation on final properties will be investigated. These efforts are 

important for developing the measurement science to predict fusion interface strength as a 

function of processing parameters. The MML effort has a strong focus on structure-property 

relationships for molecular level performance. This is an important step, but this work would be 

greatly enhanced with additional work to transition molecular-level knowledge to testing and 

qualification of AM parts. 

There are several areas where NIST laboratories may leverage core expertise to accelerate the 

measurement science delivered to the AM community. The mechanical properties of any AM 

part will be a function of the composite and includes the material properties, build geometry 

(raster angle, filament size, gap, temperature, etc.), voids and defects, and roughness. There are

many ASTM and ISO test standards available for AM materials, but a technical basis is required 

to provide the guidance for testing additive parts to account for anisotropy and develop the 

models required to predict final mechanical properties. This technical basis will transition the 

molecular structure-property measurements from MML into standards for testing coupon level 

samples in the purview of ASTM and ISO standards. Standardizing how materials are built and 

tested in order to determine mechanical and failure performance for parts in tension, 

compression, flexure, fatigue, and fracture is key to deploying engineered AM structures with 

confidence. Further, the development of composite mechanics models for properties of AM parts 

will inform the MML effort on molecular scale measurements. This engineering effort would

close the measurement loop across multiple length scales and provide a route to translate the 

innovations from molecular scale measurements into the advancement of AM part quality and 

strength. This is an area where EL and MML may leverage their respective AM programs to 

improve measurements science, standards, and the AM community. Similar examples of 

successful collaboration exist in the metal AM programs. A second area of collaboration would 

be the development of standard reference materials for printing to calibrate the performance of 

different AM machines. Ultimately, the constitutive equations, standards, and design decisions 

developed for polymer AM need to be brought into the AM workflow. This is a third area of 

collaboration between the EL and MML Additive Manufacturing efforts.

10. Conclusion and Path Forward

Polymer AM is gaining attention from many press-worthy applications that has helped drive 

advances in materials and manufacturing equipment. There has been significant investment from 

private industry and government to foster AM growth. Polymer AM equipment is becoming 

more accessible to the general public further increasing the possibility for distributed 

manufacturing of high quality parts and increasing innovation in design. Advances in machine 

design have led to AM with high performance semi-crystalline polymers and composites, which 

are creating a demand for better mechanical property measurements. AM process parameters 

exhibit a non-linear effect on mechanical properties and one of the challenging aspects is 

maximizing the fusion bond and relating process parameters to polymer structure for 

thermoplastics, semi-crystalline materials, composites, and thermosets. 
34

This report helped to outline specific measurement and standards recommendations:

1. Engineers require the ability to compare the rheological, thermal, and size distribution of 

AM raw materials. In addition, engineers should be able to compare mechanical 

properties of as received material with material properties of a extruded material. This 

will alleviate some of the unknowns that users face with printing materials from different 

lots or printing machines. A classification system should be developed for AM materials 

so that materials may be classified based on expected mechanical performance. This 

would allow engineers to identify the physical properties of the polymer such as melt 

viscosity, molecular weight, and heat capacity, so that material deposition can be 

optimized.

2. An effort should be made to identify standard reference polymers that could be used to 

validate AM machine performance.

3. Constitutive equations are required to predict the effect of print parameters on filament 

geometry and inter-diffusion of polymers.

4. A suite of standard test methods should be developed to support the measurement of 

material properties for engineering design. The test geometries developed in the standards 

should be supported by mechanical models to provide an understanding of anisotropy.

5. A better understanding of the durability of AM materials to environmental stresses such 

as weather, fatigue, creep, and thermal cycling is needed. The presence of residual stress, 

buried flaws, kissing bonds, and other stress risers will be increase the probability of 

failure under external stresses.

6. Constitutive equations for polymer structure-property relationships and intelligent 

printing design to account for intended load paths should be incorporated into the AM 

workflow to better predict AM final properties. 

7. Finally, the AM community of designers and engineers should be supported in the critical 

aspects of structural properties of polymers and composites to prevent the treatment of 

soft materials based on past experience with metallic materials.

International standards organizations, namely ASTM and ISO, have developed more than 25 

standards each (55 combined) for testing mechanical properties of polymers and composites. A 

few of the composites standards are intended for materials containing high modulus fibers and 

are not directly applicable to samples made with current AM processes. On the other hand, 

studies have shown certain composite standards actually improve test consistency on AM 

materials compared to geometries for non-composite materials. The majority of existing 

standards are applicable to testing AM produced parts, but guidance is required to specifically 

address engineering property measurements from AM processes. This report is intended to 

provide a brief survey of the landscape for polymer AM and summarize current efforts at NIST 

to identify technical gaps. The growing application of AM to the biomedical industry will require 

similar support for standards and material classification. There is an opportunity to leverage the 

efforts in MML to bridge the length scales to provide measurement science, bulk 

characterization, and standards to support the growing AM industry.
35

Acknowledgements

The author would like to thank John Slotwinski (The Johns Hopkins University Applied Physics 

Laboratory), Don Hunston (NIST/EL), Stephanie Watson (NIST/EL), Jon Seppala 

(NIST/MML), and Kalman Migler (NIST/MML) for their helpful comments, suggestions, and 

discussions concerning the development of this manuscript. 
36

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[89] ISO 14130:1997, Fibre-reinforced plastic composites – Determination of 

apparent interlaminar shear strength by short-beam method, ISO/TC 61/SC 13, Ed. 

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[92] ASTM D7078/7078M-12, Standard Test Method for Shear Properties of 

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creep, ISO/TC 61/SC 2, Ed. Switzerland: International Standards Organization, 2011.

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creep by three-point loading, ISO/TC 61/SC 2, Ed. Switzerland: International Standards 

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[99] ASTM D7774-12, Standard Test Method for Flexural Fatigue Properties of 

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under cyclic loading conditions, ISO/TC 61/SC 13, Ed. Switzerland: International 

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propagation – Linear elastic fracture mechanics (LEFM) approach, ISO/TC 61/SC 2, 

Ed. Switzerland: International Standards Organization, 2014.

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Composites, D30.06, Ed. West Conshohocken, PA: ASTM International, 2011. [Online]. 

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interlaminar fracture toughness, GIC, for unidirectionally reinforced material, ISO/TC 

61/SC 13, Ed. Switzerland: International Standards Organization, 2001.
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[105] ASTM D5528-13, Standard Test Method for Mode I Interlaminar Fracture 

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toughness, ISO/TC 61/SC 2, Ed. Switzerland: International Standards Organization, 

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International Standards Organization, 2000.

[108] ISO 13586:2000/Amd 1:2003, Guidelines for the testing of injection-moulded 

plastics containing discontinuous reinforcing fibres, ISO/TC 61/SC 2, Ed. Switzerland: 

International Standards Organization, 2003.

[109] ASTM D6068-10 , Standard Test Method for Determining J-R Curves of Plastic 

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[111] ISO 179-2:1997, Plastics – Determination of Charpy impact properties – Part 2: 

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resistance of notched specimens of plastics, D20.10, Ed. West Conshohocken, PA: 

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[115] ASTM D5961/5961M-13, Standard Test Method for Bearing Response of 

Polymer Matrix Composite Laminates, D30.05, Ed. West Conshohocken, PA: ASTM 

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[116] ASTM D6484/D6484M-14, Standard Test Method for Open-Hole Compressive 

Strength of Polymer Matrix Composite Laminates, D30.05, Ed. West Conshohocken, PA: 

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[118] ISO 12817:2013, Fibre-reinforced plastic composites – Determination of openhole compression strength, ISO/TC 61/SC 13, Ed. Switzerland: International Standards 

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