Experimentation and predictive modelling of Fused filament fabrication parts by finite element analysis and fuzzy Inference system

Abstract

This study investigates the influence of critical process parameters on the tensile strength (TS) of components fabricated using Fused Filament Fabrication (FFF) with Polylactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS) polymers. Specimens were printed with varying layer thicknesses (0.4 mm, 0.5 mm, and 0.6 mm) and different infill patterns (triangular, grid, and line) to evaluate their mechanical performance under uniaxial tensile loading. Experimental tensile testing was supported by Finite Element Method (FEM) simulations to visualize stress distributions and validate failure mechanisms. Additionally, a Fuzzy Inference System (FIS) was developed to predict TS based on processing inputs, demonstrating high predictive accuracy. The results showed that PLA samples consistently outperformed ABS, with the highest TS recorded at 43.15 MPa for PLA using 0.4 mm layer thickness and line infill. ABS achieved a maximum TS of 25.40 MPa under similar conditions with a triangular infill. FEM simulations aligned closely with experimental data, producing an average error of 6.09%, while FIS predictions demonstrated even greater accuracy with an average error of 5.00%. Analysis of Variance (ANOVA) revealed filament material as the most significant contributor to TS variation, accounting for 96.84% of the total effect. The integration of experimental testing, FEM analysis, and FIS modeling offers a comprehensive framework for optimizing structural performance in FFF-fabricated components. This approach contributes to the development of predictive methodologies for reliable, load-bearing applications in additive manufacturing.