ASTM D3039 test specimens provide the most consistent failure within the test specimen’s gage length, which is attributed to the rectangular design of the test specimen. Results indicate there is an inherent benefit to using ASTM D3039 over ASTM D638 Type I and Type more » IV test specimens for tensile testing. Here, the purpose of the study is to provide guidance on the use of existing ASTM polymer testing standards for additively manufactured polymers. This study provides evidence-based guidance through the comparison of the mechanical performance and failure acceptance rates of ASTM D3039 and ASTM D638 test specimen geometries, fabricated using FFF acrylonitrile butadiene styrene (ABS). There has been limited published research regarding the selection of an ASTM test specimen geometry for FFF polymer materials. ASTM polymer and plastic tensile test standards define criteria for acceptably tested specimens as requiring failure inside the narrow length (i.e., ASTM D638) or outside of the grips (i.e., ASTM D3039) for the results to be considered acceptable. The choice of ASTM D638 versus ASTM D3039 test specimen geometry is usually based on the perceived susceptibility of the ASTM D638 test specimens to failure within the fillet radius. When evaluating the static mechanical performance of fused filament fabrication (FFF) polymers, researchers have conducted tensile testing using American Society for Testing Materials International (ASTM) D3039 rectangular test specimens and ASTM D638 Type I and Type IV dogbone test specimens.
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