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

Luis Lisandro Lopez Taborda, Heriberto Maury, Ivan E. Esparragoza

Research output: Contribution to journalArticlepeer-review

Abstract

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.

Original languageEnglish (US)
Pages (from-to)1803-1821
Number of pages19
JournalRapid Prototyping Journal
Volume30
Issue number9
DOIs
StatePublished - Oct 24 2024

All Science Journal Classification (ASJC) codes

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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