Optimization of the Mechanical Response in MEX Additive Manufacturing of Thermoplastic Polyimide (PI): The Impact of Key Process Control Settings

> 0.71) enabled accurate prediction of mechanical responses (confirmation run error <10%). The optimized configuration yielded an improvement higher than 250% in all three of the tensile response metrics (230% for the fourth configuration). An experimentally validated, robust framework is provided herein for the tensile response of high-performance PI thermoplastics in MEX 3D printing, thus enabling its broader utilization in aerospace, electronics, and high-temperature tooling, in which performance and reliability are critical.