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The purpose of the experimental investigation was to optimize the process parameters of the fused deposition modeling (FDM) technique. The optimization of the process was performed to identify the relationship between the chosen factors and the tensile strength of acrylonitrile butadiene styrene (ABS) and carbon fiber polylactic acid (PLA) thermoplastic material, FDM printed specimens. The relationship was demonstrated by using the linear experimental model analysis, and a prediction expression was established. The developed prediction expression can be used for the prediction of tensile strength of selected thermoplastic materials at a 95% confidence level.

The Taguchi L9 experimental methodology was used to plan the total number of experiments to be performed. The process parameters were chosen as three at three working levels. The working range of chosen factors was the printing speed (60, 80 and 100mm/min), 40%, 60% and 80% as the infill density and 0.1mm, 0.2mm and 0.3mm as the layer thickness. The fused deposition modeling process parameters were optimized to get the maximum tensile strength in FDM printed ABS and carbon fiber PLA thermoplastic material specimens.

The optimum condition was achieved by the process optimization, and the desired results were obtained. The maximum desirability was achieved as 0.98 (98%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.3mm. The strength of the ABS specimen was predicted to be 23.83MPa. The observed strength value was 23.66MPa. The maximum desirability was obtained as 1 (100%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.2mm. The strength of the carbon fiber PLA specimen was predicted to be 26.23MPa, and the obtained value was 26.49MPa.

The research shows the useful process parameters and their suitable working conditions to print the tensile specimens of the ABS and carbon fiber PLA thermoplastics by using the fused deposition modeling technique. The process was optimized to identify the most influential factor, and the desired optimum condition was achieved at which the maximum tensile strength was reported. The produced prediction expression can be used to predict the tensile strength of ABS and carbon fiber PLA filaments.

The results obtained from the experimental investigation are useful to get an insight into the FDM process and working limits to print the parts by using the ABS and carbon fiber PLA material for various industrial and structural applications.

The results will be useful in choosing the suitable thermoplastic filament for the various prototyping and structural applications. The products that require freedom in design and are difficult to produce by most of the conventional techniques can be produced at low cost and in less time by the fused deposition modeling technique.

The process optimization shows the practical exposures to state an optimum working condition to print the ABS and carbon fiber PLA tensile specimens by using the FDM technique. The carbon fiber PLA shows better strength than ABS thermoplastic material.

Additive manufacturing (AM) technology has a huge influence on the real world because of its ability to manufacture massively complicated geometrics. The purpose of this study is to use CiteSpace (CS) visual analysis to identify fused deposition modeling (FDM) research and development patterns to guide researchers to decide future research and provide a framework for corporations and organizations to prepare for the development in the rapid prototyping industry. Three-dimensional printing (3DP) is defined to budget minimize manufactured input and output for aviation and the medical product industrial sectors. 3DP has implemented its potential in the Coronavirus Disease of 2019 (COVID-19) reaction.

First, 396 original publications were extracted from the web of science (WOS) with the comprehensive list and did scientometrics analysis in CS software. The parameters are specified in CS including the span (from 2011 to 2019, one year slice for the co-authorship and the co-accordance analysis), visualization (show the merged networks), specific criteria for selection (top 20%), node form (author, organization, region, reference cited; cited author, journal and keywords) and pruning (pathfinder and slicing network). Finally, correlating data was studied and showed the results of the visualization study of FDM research were shown.

The framework of FDM information is beginning to take shape. About hot research topics, there are “Morphology,” “Tensile Property by making Blends,” “Use of Carbon nanotube in 3DP” and “Topology optimization.” Regarding the latest research frontiers of FDM printing, there are “Fused Filament Fabrication,” “AM,” in FDM printing. Where “Post-processing” and “environmental impact” are the research hotspots in FDM printing. These research results can provide insight into FDM printing and useful information to consider the existing studies and developments in FDM researchers’ analysis.

Despite some important obtained results through FDM-related publications’ visualization, some deficiencies remain in this research. With >99% of articles written in English, the input data for CS was all downloaded from WOS databases, resulting in a language bias of papers in other languages and neglecting other data sources. Although, there are several challenges being faced by the FDM that limit its wide variety of applications. However, the significance of the current work concerning the technical and engineering prospects is discussed herein.

First, the novelty of this work lies in describing the FDM approach in a Scientometric way. In Scientometric investigation, leading writers, organizations, keywords, hot research and emerging knowledge points were explained. Second, this research has thoroughly and comprehensively examined the useful sustainability effects, i.e. economic sustainability, energy-based sustainability, environmental sustainability, of 3DP in industrial development in qualitative and quantitative aspects by 2025 from a global viewpoint. Third, this work also described the practical significance of FDM based on 3DP since COVID-19. 3DP has stepped up as a vital technology to support improved healthcare and other general response to emergency situations.

The purpose of this paper is to continue to describe the development of a comprehensive methodology for fully resolved numerical simulations of fused deposition modeling.

A front-tracking/finite volume method introduced in Part I to simulate the heat transfer and fluid dynamics of the deposition of a polymer filament on a fixed bed is extended by adding an improved model for the injection nozzle, including the shrinkage of the polymer as it cools down, and accounting for stresses in the solid.

The accuracy and convergence properties of the new method are tested by grid refinement, and the method is shown to produce convergent solutions for the shape of the filament, the temperature distribution, the shrinkage and the solid stresses.

The method presented in the paper focuses on modeling the fluid flow, the cooling and solidification and volume changes and residual stresses, using a relatively simple viscoelastic constitutive model. More complex material models, depending, for example, on the evolution of the conformation tensor, are not included.

The ability to carry out fully resolved numerical simulations of the fused deposition process is expected to be critical for the validation of mathematical models for the material behavior, to help explore new deposition strategies and to provide the “ground truth” for the development of reduced-order models.

The paper completes describing the development of the first numerical method for fully resolved simulation of fused filament modeling.

Fused deposition modelling (FDM) is the most economical additive manufacturing technique. The purpose of this paper is to describe a detailed review of this technique. Total 211 research papers published during the past 26 years, that is, from the year 1994 to 2019 are critically reviewed. Based on the literature review, research gaps are identified and the scope for future work is discussed.

Literature review in the domain of FDM is categorized into five sections – (i) process parameter optimization, (ii) environmental factors affecting the quality of printed parts, (iii) post-production finishing techniques to improve quality of parts, (iv) numerical simulation of process and (iv) recent advances in FDM. Summary of major research work in FDM is presented in tabular form.

Based on literature review, research gaps are identified and scope of future work in FDM along with roadmap is discussed.

In the present paper, literature related to chemical, electric and magnetic properties of FDM parts made up of various filament feedstock materials is not reviewed.

This is a comprehensive literature review in the domain of FDM focused on identifying the direction for future work to enhance the acceptability of FDM printed parts in industries.

Although the feasibility and effectiveness of the fused deposition modeling (FDM) method have been proposed and developed, studies of applying this technology to various materials are still needed for researching its applicability, especially with regard to polymer blends and composites. The purpose of this paper is to study the deposition-induced effect and the effect of compatibilizers on the mechanical properties of polypropylene and polycarbonate (PP/PC) composites.

For this purpose, three different deposition modes for PP/PC composites with or without compatibilizers were used for the FDM method and tested for tensile properties. Also, parts with the same materials were made by injection molding and used for comparison. In addition, different deposition speeds were used to investigate the different deposition-induced effects. Furthermore, the behavior of the mechanical properties was clarified with scanning electron microscope images of the fracture surfaces.

The research results suggest that the deposition orientation has a significant influence on the mechanical behavior of PP/PC composite FDM parts. The results also indicate that there is a close relationship between the mechanical properties and morphological structures which are deeply influenced by compatibilization. Compared with injection molded parts, the ductility of the FDM parts can be dramatically improved due to the formation of fibrils and micro-fibrils by the deposition induced during processing.

This is the first paper to investigate a PP/PC composite FDM process. The results of this paper verified the applicability of PP/PC composites to FDM technology. It is also the first time that the deposition-induced effect during FDM has been investigated and studied.

The purpose of this paper is to study the integration between this technology and barrel finishing (BF) operation to improve part surface quality. Fused deposition modeling (FDM) processes have limitation in term of accuracy and surface finishing. Hence, post-processing operations are needed. A theoretical and experimental investigations have been carried out.

A geometrical model of the profile under the action of machining is proposed. The model takes into account FDM formulation and allows to predict the surface morphology achievable by BF. The MR needed in the model is obtained by a particular profilometer methodology, based on the alignment of Firestone–Abbot (F–A) curves. The experimental performed on a suitable geometry validated geometrical model. Profilometer and dimensional measurements have been used to assess the output of the coupled technologies in terms of surface roughness and accuracy.

The coupling of FDM and BF has been assessed and characterized in terms of obtained part surfaces and dimension evolution. Deposition angle strongly affects the BF removal speed and alters nominal dimensions of part. The geometric profile model gave interesting information about profile morphology and machining mechanism; moreover, the height prevision allows to estimate BF working time to accomplish part requirements.

The prediction of the geometric profile as a function of FDM fabrication parameters is a powerful tool which permits to investigate surface properties such as mechanical coupling or tribological aspects. The coupling of BF and FDM has been assessed and now optimization of this process can be performed just evaluating effects of parameters.

This research has been focused to an industrial application, and results can be used in a computer-aided manufacturing. The prevision of surface obtainable by this integration is a tool to find the part optimum orientation to accomplish the drawing requirements. Both the experimental findings and the model can guide operator toward a proper process improvement, thus reducing or eliminating expensive trial and error phase in the post-processing operation of FDM prototypes.

In this paper, a novel model has been presented. It allows to know in advance profile morphology achievable by a specific surface of a FDM part after a determined BF working time. A particular application of FA curves gives the MR values.

This paper aims to present a first step toward developing a comprehensive methodology for fully resolved numerical simulations of fusion deposition modeling (FDM).

A front-tracking/finite volume method previously developed for simulations of multiphase flows is extended to model the injection of hot polymer and its cooling down.

The accuracy and convergence properties of the new method are tested by grid refinement, and the method is shown to produce convergent solutions for the shape of the filament, the temperature distribution, contact area and reheat region when new filaments are deposited on top of previously laid down filaments.

The present paper focuses on modeling the fluid flow and the cooling. The modeling of solidification, volume changes and residual stresses will be described in Part II.

The ability to carry out fully resolved numerical simulations of the fusion deposition process is expected to help explore new deposition strategies and provide the “ground truth” for the development of reduced-order models.

The present paper is the first fully resolved simulation of the deposition in fusion filament modeling.

The thermal behavior at the interfaces (of the deposited strands) during fused filament fabrication (FFF) technique strongly influences bond formation and it is a time- and temperature-dependent process. The processing parameters affect the thermal behavior at the interfaces and the purpose of the paper is to simulate using temperature-dependent (nonlinear) thermal properties rather than constant properties.

Nonlinear temperature-dependent thermal properties are used to simulate the FFF process in a simulation software. The finite-element model is first established by comparing the simulation results with that of analytical and experimental results of acrylonitrile butadiene styrene and polylactic acid. Strand temperature and time duration to reach critical sintering temperature for the bond formation are estimated for one of the deposition sequences.

Temperatures are estimated at an interface and are then compared with the experimental results, which shows a close match. The results of the average time duration (time to reach the critical sintering temperature) of strands with the defined deposition sequences show that the first interface has the highest average time duration. Varying processing parameters show that higher temperatures of the extruder and envelope along with higher extruder diameter and lower convective heat transfer coefficient will have more time available for bonding between the strands.

A novel numerical model is developed using temperature-dependent (nonlinear) thermal properties to simulate FFF processes. The model estimates the temperature evolution at the strand interfaces. It helps to evaluate the time duration to reach critical sintering temperature (temperature above which the bond formation occurs) as it cools from extrusion temperature.

The purpose of this study is to propose the use of a pre-deposition heating system for fused filament fabrication (FFF) as a means to enhance interlayer bonding by elevating the substrate temperature. The effects of the heating on thermal profile at the bonding interface and the mechanical properties of three-dimensional printed parts are investigated.

A 12-W laser head is integrated to a commercial printer as the pre-deposition heating system. The laser beam heats up substate before the deposition of a fresh filament. Effects of laser powers are investigated and the thermal profile is measured with thermocouple, infrared camera and finite element model. The correlation between the temperature at the bonding interface and the bonding quality is investigated by conducting tensile testing and neck width measurement with microscope.

The pre-deposition heating system is proven to be effective in enhancing the inter-layer strength in FFF parts. Tensile testing of specimens along build direction (Z) shows an increase of around 50% in ultimate strength. A linear relationship is observed between the pre-deposition temperature at bond interface and bonding strength. It is evident that elevating the pre-deposition temperature promotes interlayer polymer diffusion as shown by the increased neck width between layers.

Thermocouples that are sandwiched between layers are used to achieve accurate measurement of the interfacial temperature. The temperature profiles under pre-deposition heating are analyzed and correlated to the interlayer bonding strengths.

The purpose of this study is to highlight the direct fabrication of rapid tooling (RT) with desired mechanical, tribological and thermal properties using fused deposition modelling (FDM) process. Further, the review paper demonstrated development procedure of alternative feedstock filament of low-cost composite material for FDM to extend the range of RT applications.

The alternative materials for FDM and their processing requirements for fabrication in filament form as reported by various researchers have been summarized. The literature demonstrates the role of various post-processing techniques on surface finish of FDM prints. Further, low-cost materials for feedstock filament have been investigated experimentally to check their adaptability/suitability for commercial FDM setup. The approach was to realize the requirements of FDM (melt flow rate, flexibility, stiffness, glass transition temperature and mechanical strength), necessary for the successful run of an alternative filament. The effect of constituents (additives, plasticizers, surfactants and fillers) in polymeric matrix on mechanical, tribological and thermal properties has been investigated.

It is possible to develop composite material feedstock as filament for commercial FDM setup without changing its hardware and software. Surface finish of the parts can further be improved by applying various post-processing techniques. Most of the composite parts have high mechanical strength, hardness, thermal stability, wear resistant and better bond formation than standard material parts.

Future research may be focused on improving the surface quality of parts fabricated with composite feedstock, solving issues related to the uniform distribution of filled materials during the fabrication of feedstock filament which in turns further increases mechanical strength, high dimensional stability of composite filament and transferring the technology from laboratory scale to various industrial applications.

Potential applications of direct fabrication with RT includes rapid manufacturing (RM) of metal-filled parts and ceramic-filled parts (which have complex shape and cannot be rapidly made by any other manufacturing techniques) in the field of biomedical and dentistry.

This new manufacturing methodology is based on the proper selection and processing of various materials and additives to form high-performance, low-cost composite material feedstock filament (which fulfil the necessary requirements of FDM process). Finally, newly developed feedstock filament material has both quantitative and qualitative advantage in RT and RM applications as compared to standard material filament.