A 3D printed tensile testing system for micro-scale specimens.

This article presents the development and validation of a cost-effective, 3D printed tensile testing system designed for mechanical characterization of micro-scale specimens with cross-sectional dimensions on the order of tens of micrometers. The system integrates built-in force sensors, self-aligning loading frames, and optical microscopy with digital image correlation (DIC) for simultaneous force and strain measurements, enabling tailored force measurement ranges from 0.001 to 1 N. Finite element analysis identified angular misalignment as the dominant source of measurement error, which was mitigated by modifying the loading frame design. Experimental validation using fine copper wires (10–25 µm diameter) demonstrated that the system accurately measures mechanical properties consistent with known bulk copper values, highlighting its reliability, flexibility, and accessibility for micro-scale mechanical testing.