Low‐Velocity Impact Response and Damage Mechanisms of 3D Printed ASA‐Glass Fiber Composites

ABSTRACT This study investigates the low velocity impact behavior and underlying damage mechanisms of 3D printed acrylonitrile styrene acrylate reinforced with short glass fibers (ASA + GF) composites. Despite widespread use of glass fiber reinforced thermoplastics, the impact behavior of additively manufactured ASA + GF composites remains insufficiently studied. This study addresses this gap using drop weight impact testing combined with microscopic and profilometry analysis. The key novelty is identifying a transition in failure behavior from indentation dominated response at low impact energy to architecture‐controlled fracture at higher energy, governed by raster orientation. At 18 J impact energy, 0°/90° panels exhibited approximately 18% higher peak force compared to 45°/−45° panels, indicating superior resistance to initial penetration. In contrast, 45°/−45° panels showed approximately 32% greater maximum displacement and 35% higher energy dissipation, reflecting more progressive deformation behavior. Microscopic analysis of crack paths and fiber crack interactions demonstrated that in 0°/90° panels, fibers frequently intersected the crack plane, providing effective crack bridging and enhancing peak load capacity. In 45°/−45° panels, fibers were more aligned with the crack path, promoting shear driven interfacial sliding and fiber pullout, which dissipated energy over larger deformations. These observations establish a clear correlation between printing architecture, fiber alignment, and anisotropic fracture behavior.