Characterization of PC-ABS and PETG Multi-Material Laminates Fabricated by MEX Method

Material-extrusion (MEX) printing with automated filament switching enables single-build multi-material laminates, but interfaces between dissimilar polymers may govern failure. Here, monolithic PETG, monolithic PC–ABS, and an alternating PETG/PC–ABS laminate (COMP) with 0.2 mm laminae (4 mm total) were fabricated and benchmarked. Tensile behavior was measured using ISO 527-2 Type 1B specimens at 5 and 50 mm/min, complemented by three-point bending in horizontal/vertical orientations, unnotched Charpy impact (ISO 179), Shore D hardness (ISO 868), and SEM fractography. COMP delivered the highest horizontal flexural strength (159.82 ± 25.42 MPa), exceeding both single-material baselines, indicating improved bending load capacity in the preferred orientation. In Charpy impact, COMP absorbed more energy than PETG in the horizontal condition (0.86 ± 0.14 J vs. 0.57 ± 0.06 J) but remained below PC–ABS. In tension, COMP strength decreased by ~21–23% relative to PETG and by ~5–6% relative to PC–ABS at both speeds, consistent with interface-controlled damage. SEM revealed void-assisted crack initiation and interfacial debonding aligned with raster paths, highlighting interfacial strengthening and porosity reduction as key routes to improve tensile performance while retaining favorable flexural and impact response.