Polymer Testing 110 (2022) 107581

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Polymer Testing
journal homepage: www.elsevier.com/locate/polytest

Tensile test of additively manufactured specimens with external notch

removed via laser cutting in material extrusion
Seong Je Park a, Ji Eun Lee b, Sun Chul Jin c, Nak-Kyu Lee d, Kyunsuk Choi e, Suk-Hee Park f, **,
Yong Son a, *
a
Additive Manufacturing Innovation Agency, 113-58 Seohaean-ro, Siheung-si, Gyeonggi-do, 15014, Republic of Korea
b
Advanced Textile R&D Department, Korea Institute of Industrial Technology, 143 Hanggaul-ro, Sangnok-gu, Ansan-si, Gyeonggi-do, 15588, Republic of Korea
c
Chemical Research Center, Samyang Co., 730 Daedeok-daero, Yuseong-gu, Daejeon, 34055, Republic of Korea
d
Korea Institute of Industrial Technology, 89 Yangdaegiro-gil, Ipjang-myeon, Seobuk-gu, Cheonan-si, Chungcheongnam-do, 31056, Republic of Korea
e
Department of Industry-University Convergence, Hanbat National University, 125 Dongseodae-ro, Yuseong-gu, Daejeon-si, 34014, Republic of Korea
f
School of Mechanical Engineering, Pusan National University, 2 Busandaehak-ro, 63 beon-gil, Geumjeong-gu, Busan, 46241, Republic of Korea

A R T I C L E I N F O A B S T R A C T

Keywords: The specimens fabricated by material extrusion (ME)-type additive manufacturing (AM) have external notches
Additive manufacturing (AM) because of their deposition mechanism. During tensile tests, accurate results cannot be obtained because the
Material extrusion (ME) external notch causes stress concentration and induces fractures outside the gauge length. In this study, using
Tensile test
laser cutting, we removed the notch of specimens without damage to the specimens. By removing the notch and
Stress concentration
Laser cutting
stress concentration in specimens, fractures were induced within the gauge length with a 62% probability,
whereas the specimens in which the notch and stress concentration were not removed had a 27% probability.
Through this evaluation method, the tensile results of the specimens for various polymers can be compared fairly
and quantitatively with a small standard deviation in terms of the tensile strength and elongation at break be­
tween the specimens.

1. Introduction deposited vertically to the direction of tension (transverse specimen)

Currently, additive manufacturing (AM) is the most popular process
because it enables the fabrication of three-dimensional (3D) parts based
on CAD data without any restrictions on the shape of the user’s idea [1].
The AM process can be classified into seven types based on ASTM
F2792-12a according to the material used and deposition mechanism
[2]. The material extrusion (ME) method, in which filament-type ther­
moplastic materials are melt-extruded through a heating block and
nozzle and deposited on a bed, layer by layer, is the most studied method
because it is easy to process with various materials [3]. Owing to the
non-continuous deposition characteristics of ME, the mechanical prop­
erties depend on the adhesive property of materials and can result in
various strengths depending on the deposition direction [4–6]. For
example, a specimen deposited horizontally to the direction of tension
(longitudinal specimen) exhibits a tensile strength of approximately
70–90% of the bulk material, and the level of mechanical properties
inherent in the material can be identified. However, a specimen
exhibits the lowest tensile strength of approximately 40–60% of the bulk
material, and the level of adhesion of the material can be identified [7].
Because the specimen fabricated by mixing in various directions has a
value between the transverse and longitudinal specimen, the anisotropy
can be quantitatively identified by the ratio of the strength of the
transverse and longitudinal specimens [6,8]. Many researchers fabri­
cated transverse and longitudinal specimens with various materials and
process parameters and quantitatively identified anisotropy [6,9]. In
other words, the ratio of the tensile strength of transverse and longitu­
dinal specimens is a concept in the ME method that compares specimens
made of various materials and process parameters in one standardized
manner [10].
However, in previous studies, experiments were conducted without
eliminating the adverse effects of the stress concentration from the
external notch of the transverse specimens [7,10,11]. Therefore, the
reproducibility of the specimen fracture mode is poor; particularly, in
the case of a tensile test, it is not only difficult to conduct a fair test due

* Corresponding author.
** Corresponding author.
E-mail addresses: selome815@pusan.ac.kr (S.-H. Park), sonyong@kitech.re.kr (Y. Son).

https://doi.org/10.1016/j.polymertesting.2022.107581
Received 20 January 2022; Received in revised form 28 March 2022; Accepted 6 April 2022
Available online 12 April 2022
0142-9418/© 2022 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
S.J. Park et al.
to fractures outside the gauge length but also the standard deviation of
the tensile strength and elongation at the break of specimens is high
although they are produced under the same process conditions [12–15].
Even if ME equipment having a super high resolution developed, frac­
ture outside the gauge length and high standard deviation will be un­
avoidable because of external notch [16]. To prevent fractures outside
the gauge length, some researchers have changed the dog bone-shaped
tensile specimen to a rectangular specimen [2,6,17]. Furthermore, the
external notch of the specimen can be removed using pressing, waterjet,
saw, milling, and laser cutting methods. For pressing, a separate mold
production is required depending on the shape of the specimen, and
polymers with high brittleness are difficult to use because of cracking
[18]. In the case of the waterjet, separate die are not required, but with
polymers that are weak against humidity, moisture absorption caused by
the waterjet decreases the physical properties [19,20]. Saw and milling
can be used in the cutting method [21,22]. Because the saw and milling
process is also accompanied by water to prevent thermal degradation, it
has a negative effect in terms of the physical properties like the waterjet
process. Laser cutting is widely used for cutting polymers in actual in­
dustrial sites, and if the energy density, such as the laser power and
speed is optimized, clean cutting is achieved without the heat affected
zone (HAZ) of the material [23–26]. Furthermore, laser cutting was used
for the parts fabricated by ME to verify that the cutting method is
appropriate for ME parts [27–29].
In this study, the stress concentration from external notches was
evaluated using the models of the longitudinal and transverse specimens
through computer-aided engineering (CAE) at first. Further, specimens
were additively manufactured to understand the effect of the external
notch on the actual parts. To prepare a specimen with an external notch,
transverse specimens were additively manufactured using ME and to
prepare one without an external notch, the external notch was elimi­
nated from the specimen fabricated by ME through laser cutting.
Therefore, the tensile behaviour was compared and analysed according
to whether the external notch existed or not. Based on the overall ex­
periments in this study, the authors inferred that a fairer experimental
guide should be presented for ME users to determine the level of
adhesion of ME materials.
2. Materials and method
2.1. CAE of tensile specimens
Structural analysis was performed using ANSYS to determine the
stress distributed inside the specimen in the tensile load. Physical
properties such as the elastic modulus and ultimate tensile strength
provided by ABS Plus (Stratasys, U.S.A.) were used. The shape within
the gauge length of ASTM D638 No. 1 was selected as the model. For the
longitudinal specimen, a rectangular shape without a notch was used,
whereas for the transverse specimen, an external notch was modelled
onto the rectangular shape to determine the effect of the stress con­
centration. For the boundary condition, to simulate an environment
similar to the tensile test, the analysis was conducted with one side of the
model set to 0 as the remote displacement. For the opposite side, because
the ABS Plus material exhibits an elongation at a break of approximately
1% in the transverse direction, the displacement was set to 0.5 mm,
which is approximately 1% of the gauge length [7].
2.2. Preparation of tensile specimens
Commercial materials (ABS Plus Stratasys, U.S.A.) and equipment
(Fortus 250mc, Stratasys) were used to determine the effect of stress
concentration from the external notch of the specimen on the tensile
properties. The values of the nozzle temperature, chamber temperature,
nozzle speed, etc. presented by Stratasys were used. The tensile spec­
imen was deposited in the transverse direction of the x-y plane, and the
layer height and layer width were 0.254 mm and 0.4 mm, respectively. A
2
Polymer Testing 110 (2022) 107581
specimen with an external notch was additively manufactured in the
shape of ASTM D638 No. 1, and no post-processing was performed. A
specimen without an external notch was additively manufactured in a
rectangular shape (180 × 25 × 3.2 mm) and then cut into the shape of
ASTM D638 No. 1 using a laser cutter (Xcut1390, Legens, Republic of
Korea). A CO2 laser cutter with maximum power and a speed of 150 W
and 300 mm/s, respectively, was used. The tensile specimens were cut
under optimal conditions to minimize the HAZ by controlling the power
and speed of the laser cutter.
2.3. Tensile testing
The tensile specimens were set onto a universal testing machine
(DTU-900, Daekyung tech., Republic of Korea). All tests were conducted
at a tensile speed of 5 mm/min. A tensile test was conducted on 30
specimens for the case of specimens with an external notch, and the
tensile strength and elongation during breakage were calculated only for
those fractured within the gauge length. For the specimens that had their
external notch removed using the laser cutting, the tensile test was
performed until the number of samples fractured within the gauge
length matched that of the samples with the notch fail within the gauge
length. Therefore, the tensile strength and elongation during breakage
were compared using the same number of specimens.
3. Results
3.1. Comparison of stress concentration of specimens via CAE
Fig. 1 shows the two deposition directions among the specimens
produced by the ME. Fig. 1(a) shows a longitudinal specimen with the
highest tensile strength and Fig. 1(b) shows a transverse specimen with
the lowest tensile strength. As shown in Fig. 1(b), stress concentration
occurs owing to the external notch in the tensile load. The stress con­
centration may be the cause of random fracture locations and irregular
tensile behaviour during tensile testing. Therefore, the effect of the
external notch on the specimen was analysed using structural analysis.
Fig. 2 shows the internal stress distribution results from the structural
analysis. Analysis within the gauge length is important because the
tensile strength and elongation can be accurately measured only when
the fracture occurs within the gauge length during tensile testing. As
shown in Fig. 2(a), the geometry of the gauge length was selected as the
analysis model. Fig. 2(b) and (c) show the internal stress distribution of
the longitudinal and transverse models, respectively. With the specimen
without an external notch, such as the longitudinal model, an internal
stress of approximately 11 MPa was uniformly generated, whereas, with
the specimen with an external notch, such as the transverse model, a
stress concentration of approximately 13 MPa was generated. This stress
concentration acts as a defect in the tensile test, which causes random
fracture locations and irregular tensile behaviour. Therefore, the need to
eliminate the stress concentration effect in the transverse direction
specimen was indirectly confirmed through CAE.
3.2. Comparison of fracture behavior with and without notch specimens
In previous CAE, there was no stress concentration with the longi­
tudinal specimen, which resulted in an even distribution of the internal
stress, whereas stress concentration was observed with the transverse
specimen caused by the external notch. Therefore, in this study, the
fracture pattern and tensile behaviour of the specimen were compared
and analysed based on whether an external notch was present in the
transverse specimen. Fig. 3 shows the fractured specimen for the tensile
test result of the transverse specimen with the external notch. For this
case, 8 of the 30 specimens, that is, 27%, fractured within the gauge
length. This shows that the external notch affected the stress concen­
tration. To eliminate the effect of stress concentration by removing the
external notch, a specimen without a notch was produced through laser
S.J. Park et al. Polymer Testing 110 (2022) 107581

Fig. 1. Two types of deposition directions for (a) longitudinal and (b) transverse specimen in ME.

Fig. 2. (a) Region of interest for CAE in tensile specimen. The CAE results for (b) longitudinal and (c) transverse specimen.

cutting as shown in Fig. 4(a). The external shape of the specimen before
and after the notch that was removed was confirmed through OM images
as shown in Fig. 4(b). It can be observed that the external notch of the
specimen was neatly removed after the laser cutting process. Fig. 4(c)
compares the laser cutting conditions and shape cutting of the ABS
material. The specimen that was cut with relatively high energy resulted
in irregular light reflection because of HAZ causing overheating inside
the specimen [30,31], whereas the specimen that was cut with low
power caused a burr on the outside owing to insufficient energy [32,33].
The 76 W specimen had a neat cut without HAZ and burr. The HAZ of
ABS due to the laser energy is approximately 0.4–0.9 mm [34]. The HAZ
in this study applies to this level. In this optimal condition of laser

3
S.J. Park et al. Polymer Testing 110 (2022) 107581

Fig. 3. Photo of fractured specimen after tensile test for specimens with notch (Red highlighting: Fractured specimens out of gauge length). (For interpretation of the
references to colour in this figure legend, the reader is referred to the Web version of this article.)

Fig. 4. (a) Schematic for removing notch of specimens via laser. (b) OM image for specimen before and after removing notch. (c) Quality of specimen according to
laser parameter. The SEM image for the cutting surface of (d) high energy and (e) optimized energy.

cutting, the laser cuts the specimen by approximately 0.2 mm on one

side. To compensate for this, the laser path was scaled up by 0.2 mm to
correspond with the ASTM D638 No.1 standard. Particularly, the surface
roughness is 6.9 μm, which is a superior favourable to the previous study
[27]. Fig. 3(d) and (e) represent the cutting surface of high and opti­
mized energy, respectively. The high energy case exhibits a rough
wrinkle, whereas the optimized energy exhibits a smooth surface. The
rough wrinkles are also observed in other polymers such as poly­
methylmethacrylate (PMMA), polyetherimide (PEI), and polypropylene
(PP) with a high laser energy [35,36]. Therefore, the specimen was cut
with a laser speed of 10 mm/s and laser power of 76 W to remove the
external notch. To compare the tensile results with that of the specimen
with the external notch, a tensile test was conducted until the number of
fractured specimens within the gauge length reached 8. Fig. 5 shows the Fig. 5. Photo of fractured specimen after tensile test for specimens without
fractured specimen, which had the external notch removed by laser notch (Red highlighting: Fractured specimens out of gauge length). (For
cutting, after completing the tensile test. A total of 13 specimens were interpretation of the references to colour in this figure legend, the reader is
tested and 8 fractured specimens within the gauge length were obtained. referred to the Web version of this article.)
This shows that for approximately 62% of tensile specimens that had the
external notch removed by laser cutting, fractures occurred within the 3.3. Comparison of tensile results with and without notch specimens
gauge length. The number of specimens that fractured within the gauge
length increased significantly owing to the elimination of the stress The ratio of the fracture within the gauge length increased for the
concentration effect caused by the external notch. This reduces the time specimen that had the external notch removed. However, if laser cutting
and economic loss in the specimen production and tensile testing, and has a negative impact on the tensile properties, it would be deemed
simultaneously makes it possible to test with a fair specimen. impractical. Generally, it is reported that as the laser energy increases,

4
S.J. Park et al.
the surface roughness of the cutting surface is poor and the mechanical
properties are degraded because of the increased HAZ [29,34,37].
Therefore, based on the optimized laser cutting conditions, the tensile
properties of the specimen with and without the external notch were
compared. Fig. 6(a) and (b) compare the stress-strain curves of the
specimen with and without the external notch. The stress-strain curves
in Fig. 6(a) and (b) indicate that similar tensile behaviour is exhibited for
all specimens that had the external notch removed by laser cutting
compared to the specimens with the external notch. All the specimens
exhibited similar tensile behaviour because it is possible to produce fair
and uniform specimens with the absence of stress concentration from the
removal of the external notch. Fig. 6(c) and (d) compare the ultimate
tensile strength and elongation at break of the specimen with the
external notch and the specimen without the external notch. The
average ultimate tensile strength and elongation at break were similar in
both cases, but it can be observed that the standard deviation of the
specimen with the external notch removed is significantly lower than
that of the specimen with the external notch. This is because laser cut­
ting removed the external notch without negatively impacting the ma­
terial. By removing the external notch without HAZ and negative effects,
laser cutting induced fractures within the gauge length and a low stan­
dard deviation among the specimens. Therefore, when conducting
various studies, such as identifying the mechanical properties of speci­
mens fabricated by the ME method, the removal of the external notch
will provide a more accurate and fair result.
4. Discussion
4.1. Stress concentration
Maximum stress due to the stress concentration is calculated by Eq.
(1) [38].
σmax = σnom × kt
where σnom is the nominal stress and kt is the stress concentration factor.
Fig. 6. Stress-strain curves for specimens (a) with notch and (b) without notch. The results of the tensile test in terms of (c) tensile strength and (d) elongation at
break of specimens with and without notch.
Polymer Testing 110 (2022) 107581
As shown in Fig. 7 [39], kt with a shape similar to the notch in this study
is shown. The 2 l/d corresponding to the x-axis of Fig. 7 is approximately
0.5 based on Fig. 4(b) in this paper. Thus, Kt is similar to 1. This is why
the specimen without the notch did not increase in tensile strength
compared to the specimen with the notch. Instead, the notch was
removed to reduce the standard deviation of the tensile strength be­
tween the specimens and induced a fracture in the gauge length.
4.2. Tensile test specimens
For specimens manufactured by injection molding, there are tensile
test (ASTM D638), compression test (ASTM D695) and flexural test
(ASTM D790) standards. However, in the case of specimens produced by
additive manufacturing, there is no test standard. Therefore, it follows
the injection molding standard. In this respect, many errors are found in
AM specimens such as the fracture external gauge length. Most re­
searchers change the shape of the specimen to induce fractures in the
gauge length because stress concentration occurs in the dog-bone tensile
specimen [6,40] or the non-uniform thermal history accumulates [2].
The authors deduce that test standards suitable for AM characteristics
(1)
Fig. 7. Stress concentration factor.
5
S.J. Park et al.
should be established. Thus, the authors proposed a method of following
the existing standards without changing the shape of the tensile spec­
imen in the specific infill pattern.
5. Conclusion
Because of the non-continuous processing characteristics of the ME,
various strengths can result depending on the deposition direction. In
the case of specimens deposited in the transverse direction, external
notches cause stress concentration to be distributed inside the speci­
mens, which induces random fracture locations and high standard de­
viations for each specimen during tensile tests. In this study, laser
cutting was used to remove the external notch and cutting was per­
formed under optimal conditions to minimize HAZ on the material.
Tensile test results showed that the tensile strength and elongation
during breakage were similar in both cases of the specimen, with and
without the external notch. Moreover, within the gauge length,
approximately 27% of specimens with the external notch and approxi­
mately 62% of specimens without the external notch were fractured. By
removing the external notch through laser cutting to eliminate the
negative effects, it was possible to conduct testing with a fair specimen.
Author statement
Seong Je Park: Conceptualization, Methodology, Investigation, Data
curation, Formal analysis, Writing – original draft. Ji Eun Lee: Concep­
tualization, Methodology, Formal analysis. Sun Chul Jin: Resources,
Methodology. Nak-Kyu Lee: Visualization, Funding acquisition, Project
administration. Kyunsuk Choi: Methodology, Funding acquisition. Suk-
Hee Park: Conceptualization, Methodology, Investigation, Data cura­
tion, Formal analysis, Writing – original draft. Yong Son: Conceptuali­
zation, Funding acquisition, Project administration, Writing – review &
editing.
Declaration of competing interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
the work reported in this paper.
Acknowledgments
This work was supported by the Industrial Fundamental Technology
Development Program funded by the Ministry of Trade, Industry and
Energy (MOTIE) of Korea (20001221, Development of high strength and
fatigue resistance alloy and manufacturing technology for root analogue
dental implants) and a KITECH (Korea Institute of Industrial Technol­
ogy) internal project (EH220013, Development of 3D printing
commercialization technology for military parts and demonstration
support technology). The 3D printing machine was developed with the
aid of Lincsolution Co.
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