Design methodology for fused filament fabrication with failure theory: framework, database, design rule, methodology and study of case

Purpose: Additive manufacturing (AM) is growing economically because of its cost-effective design flexibility. However, it faces challenges such as interlaminar weaknesses and reduced strength because of product anisotropy. Therefore, the purpose of this study is to develop a methodology that integrates design for additive manufacturing (AM) principles with fused filament fabrication (FFF) to address these challenges, thereby enhancing product reliability and strength.

Design/methodology/approach: Developed through case analysis and literature review, this methodology focuses on design methodology for AM (DFAM) principles applied to FFF for high mechanical performance applications. A DFAM database is constructed to identify common requirements and establish design rules, validated through a case study.

Findings: Existing DFAM approaches often lack failure theory integration, especially in FFF, emphasizing mechanical characterizations over predictive failure analysis in functional parts. This methodology addresses this gap by enhancing product reliability through failure prediction in high-performance FFF applications.

Originality/value: While some DFAM methods exist for high-performance FFF, they are often specific cases. Existing DFAM methodologies typically apply broadly across AM processes without a specific focus on failure theories in functional parts. This methodology integrates FFF with a failure theory approach to strengthen product reliability in high-performance applications.

The version of record is available at https://doi.org/10.1108/RPJ-04-2024-0159. The full citation is as follows: [Design methodology for fused filament fabrication with failure theory: framework, database, design rule, methodology and study of case. Rapid Prototyping Journal 30, 9 p1803-1821 (2024)]. 'This author accepted manuscript is deposited under a Creative Commons Attribution Non-commercial 4.0 International (CC BY-NC) licence. This means that anyone may distribute, adapt, and build upon the work for non-commercial purposes, subject to full attribution. If you wish to use this manuscript for commercial purposes, please contact permissions@emerald.com'

Files

Metadata

Work Title Design methodology for fused filament fabrication with failure theory: framework, database, design rule, methodology and study of case
Access
Open Access
Creators
  1. Luis Lisandro Lopez Taborda
  2. Heriberto Maury
  3. Ivan E. Esparragoza
Keyword
  1. Design Methodology for Additive Manufacturing (DFAM)
  2. Failure theory
  3. Mechanical strength
  4. Fused Filament Fabrication (FFF)
  5. Fused Deposition Modeling (FDM)
License CC BY-NC 4.0 (Attribution-NonCommercial)
Work Type Article
Publisher
  1. Rapid Prototyping Journal
Publication Date August 27, 2024
Publisher Identifier (DOI)
  1. https://doi.org/10.1108/RPJ-04-2024-0159
Deposited February 27, 2025

Versions

Analytics

Collections

This resource is currently not in any collection.

Work History

Version 1
published

  • Created

    February 27, 2025 20:23 by Researcher Metadata Database

  • Added DMFFF-AAM.pdf

    February 27, 2025 20:23 by Researcher Metadata Database

  • Added Creator Luis Lisandro Lopez Taborda

    February 27, 2025 20:23 by Researcher Metadata Database

  • Added Creator Heriberto Maury

    February 27, 2025 20:23 by Researcher Metadata Database

  • Added Creator Ivan E. Esparragoza

    February 27, 2025 20:23 by Researcher Metadata Database

  • Published

    February 27, 2025 20:23 by Researcher Metadata Database

  • Updated

    February 27, 2025 21:04 by [unknown user]

  • Updated Keyword, Description, Publication Date Show Changes

    March 05, 2025 12:30 by avs5190

    Keyword
    • Design Methodology for Additive Manufacturing (DFAM), Failure theory, Mechanical strength, Fused Filament Fabrication (FFF), Fused Deposition Modeling (FDM)
    Description
    • Purpose: Additive manufacturing (AM) is growing economically because of its cost-effective design flexibility. However, it faces challenges such as interlaminar weaknesses and reduced strength because of product anisotropy. Therefore, the purpose of this study is to develop a methodology that integrates design for additive manufacturing (AM) principles with fused filament fabrication (FFF) to address these challenges, thereby enhancing product reliability and strength. Design/methodology/approach: Developed through case analysis and literature review, this methodology focuses on design methodology for AM (DFAM) principles applied to FFF for high mechanical performance applications. A DFAM database is constructed to identify common requirements and establish design rules, validated through a case study. Findings: Existing DFAM approaches often lack failure theory integration, especially in FFF, emphasizing mechanical characterizations over predictive failure analysis in functional parts. This methodology addresses this gap by enhancing product reliability through failure prediction in high-performance FFF applications. Originality/value: While some DFAM methods exist for high-performance FFF, they are often specific cases. Existing DFAM methodologies typically apply broadly across AM processes without a specific focus on failure theories in functional parts. This methodology integrates FFF with a failure theory approach to strengthen product reliability in high-performance applications.
    • Purpose: Additive manufacturing (AM) is growing economically because of its cost-effective design flexibility. However, it faces challenges such as interlaminar weaknesses and reduced strength because of product anisotropy. Therefore, the purpose of this study is to develop a methodology that integrates design for additive manufacturing (AM) principles with fused filament fabrication (FFF) to address these challenges, thereby enhancing product reliability and strength.
    • Design/methodology/approach: Developed through case analysis and literature review, this methodology focuses on design methodology for AM (DFAM) principles applied to FFF for high mechanical performance applications. A DFAM database is constructed to identify common requirements and establish design rules, validated through a case study.
    • Findings: Existing DFAM approaches often lack failure theory integration, especially in FFF, emphasizing mechanical characterizations over predictive failure analysis in functional parts. This methodology addresses this gap by enhancing product reliability through failure prediction in high-performance FFF applications.
    • Originality/value: While some DFAM methods exist for high-performance FFF, they are often specific cases. Existing DFAM methodologies typically apply broadly across AM processes without a specific focus on failure theories in functional parts. This methodology integrates FFF with a failure theory approach to strengthen product reliability in high-performance applications.
    Publication Date
    • 2024-10-24
    • 2024-08-27