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<p>Among the various additive manufacturing (AM) techniques, fused filament fabrication (FFF) stands out for its widespread use owing to its affordability and ease of operation. However, FFF parts often exhibit inherent defects (such as porosity), which can significantly impact their mechanical properties. In this study, the influence of infill density on void formation and its effects on the mechanical properties of FFF parts is investigated through a combination of experimental, analytical, and computational analyses. PLA FFF samples with varying infill densities were manufactured and characterized to assess the part microstructures. Uniaxial quasi-static tensile tests were conducted to analyze the effective mechanical properties of the printed PLA FFF parts. A new analytical model was proposed and compared to conventional analytical models to predict the stiffness of FFF porous parts. Various 2D and 3D computational finite element (FEA) models were developed to capture the tensile behavior of FFF parts based on dense and porous structures with a density-dependent multi-linear hardening model. The optimal 2D and 3D FEA models showed excellent FEA predictions with average errors of 0.5%/0.7% and 0.8%/0.8% for E/UTS, respectively. These results were achieved with a combination of the proposed analytical model and the density-dependent multi-linear hardening model.</p>

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Experimental investigation and computational modeling of voids in fused filament fabrication parts using a novel analytical model and a porosity-dependent hardening function

  • 期刊论文

  • 发表日期：

    2026年6月1日

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  • Mosa Almutahhar,
  • Ali AlHajeri,
  • Abba A. Abubakar,
  • Jafar Albinmousa,
  • Khaled Al-Athel,
  • Usman Ali

摘要

Among the various additive manufacturing (AM) techniques, fused filament fabrication (FFF) stands out for its widespread use owing to its affordability and ease of operation. However, FFF parts often exhibit inherent defects (such as porosity), which can significantly impact their mechanical properties. In this study, the influence of infill density on void formation and its effects on the mechanical properties of FFF parts is investigated through a combination of experimental, analytical, and computational analyses. PLA FFF samples with varying infill densities were manufactured and characterized to assess the part microstructures. Uniaxial quasi-static tensile tests were conducted to analyze the effective mechanical properties of the printed PLA FFF parts. A new analytical model was proposed and compared to conventional analytical models to predict the stiffness of FFF porous parts. Various 2D and 3D computational finite element (FEA) models were developed to capture the tensile behavior of FFF parts based on dense and porous structures with a density-dependent multi-linear hardening model. The optimal 2D and 3D FEA models showed excellent FEA predictions with average errors of 0.5%/0.7% and 0.8%/0.8% for E/UTS, respectively. These results were achieved with a combination of the proposed analytical model and the density-dependent multi-linear hardening model.