A review on fused deposition modeling (FDM)-based additive manufacturing (AM) methods, materials and applications for flexible fabric structures

Fused Deposition Modeling (FDM) is an extrusion type additive manufacturing (AM) method in which a molten polymer is selectively extruded in layer-by-layer manner. Although there are several other AM techniques, FDM is a suitable method to produce fabric structures as it is capable of processing polymers and is widely used in various engineering applications. This article summarizes the current research works in characterization of FDM parts, advancements in materials used in FDM and latest works related to making fabric samples using FDM. The results show that the mechanical properties and surface quality are compromised in FDM parts. Strength and flexibility with better surface finishing are essential parameters in fabric structures. There are mainly two techniques that are explored by researchers to enhance the quality of the parts. The first is optimizing process parameters and the second is improving material quality. FDM process parameters like extrusion temperature, layer height, print speed and built orientation can significantly influence the quality of the parts. Optimizing these parameters can significantly enhance the strength of the fabric produced. Moreover, a great amount of impetus is given to improve material by reinforcing it and making polymer blends with specific qualities. There has been studies related to the development of fabric structures and deposition of polymers on fabrics with FDM. It is concluded that the major concern with such structures is strength and processability. To address these issues, optimizing process parameters and developing new filaments for exclusively making fabrics can be the future work in this area.