Miniature bending test for localized mechanical property assessment of additively manufactured material

Characterizing local mechanical properties in additivelymanufactured (AM) components is critical for design and qualification, yet challenging due to process-induced heterogeneity. A significant gap exists in robust methodologies for local bending assessment, a dominant loading mode in common AM structures like lattices. This study introduces and validates a novel Miniature Bending Test (MBT) utilizing sub-millimeter, C-shaped specimens fabricated from Ti6Al4V via Laser Powder Bed Fusion (LPBF). As-built specimens (mean radius r ≈ 0 . 60 mm , thickness t ≈ 0 . 20 mm ) were subjected to an opening load using a custom fixture. The method demonstrated excellent repeatability, yielding a highly linear force–displacement response and a compliance-corrected experimental stiffness of 23 . 13 ± 0 . 64 N/mm. This result showed poor agreement with an analytical model based on design dimensions (12.75 N/mm) but agreed well with predictions using measured as-built dimensions from analytical model based on bending ( 28 . 39 ± 0 . 63 N/mm), bending, tension and shear ( 25 . 83 ± 0 . 58 N/mm) and a Finite Element Analysis (24.54 N/mm). The findings underscore the critical impact of manufacturing deviations on mechanical performance at this scale. The MBT has potential to become a robust and sensitive methodology for qualifying local elastic properties, providing a vital tool for the certification of complex AM components. • Novel Miniature Bending Test (MBT) is developed for sub-millimeter scale assessment of additively manufactured components. • MBT successfully characterizes localized mechanical properties (stiffness) of Laser Powder Bed Fusion (LPBF) Ti6Al4V C-shaped specimens (r ≈ 0.60 mm). • The method demonstrates excellent repeatability and a highly linear elastic response. • Analytical models based on nominal design dimensions poorly predict stiffness, highlighting the critical impact of manufacturing deviations at the micro-scale. • Predictions using measured as-built geometry (FEA: 24.54 N/mm) agree well with experimental results (23.13 ± 0.64 N/mm), validating the MBT for structural qualification.