Optimizing FDM/FFF in Additive Manufacturing: A Review of Process Parameters and Material Impacts on Mechanical Properties

Abstract

This paper examines the evolution, processes, and optimization of Fused Deposition Modeling (FDM)/Fused Filament Fabrication (FFF) in additive manufacturing, synthesizing insights from existing literature on its mechanical properties and process parameters. Tracing its origins to rapid prototyping in the late 1980s, the paper highlights the advantages of FDM/FFF, such as cost-effectiveness and reduced material waste, while also addressing challenges like limited part strength. It consolidates knowledge on commonly used materials polylactic acid, acrylonitrile butadiene styrene, polycarbonate, and nylon through comparative analyses of their mechanical and thermophysical properties. The review critically assesses key process parameters, including raster angle, layer height, infill density, infill pattern, build orientation, printing speed, and nozzle diameter, drawing from diverse studies to explore their influence on part quality. Key findings include the potential of a 45°/-45° raster angle and a 0.2 mm layer height to enhance tensile strength, as well as the trade-offs associated with higher infill densities, which improve energy absorption but increase printing time. The paper identifies gaps in dimensional accuracy and material innovation, proposing future research directions to advance FDM/FFF applications across industries.