Application of Numerical Modeling and Finite Element Analysis in Fused Filament Fabrication: A Review

Additive manufacturing (AM) is not necessarily a new process but an advanced method for manufacturing complex three-dimensional (3D) parts. Among the several advantages of AM are the affordable cost, capability of building objects with complex structures for small-batch production, and raw material versatility. There are several sub-categories of AM, among which is fused filament fabrication (FFF), also commonly known as fused deposition modeling (FDM). FFF has been one of the most widely used additive manufacturing techniques due to its cost-efficiency, simplicity, and widespread availability. The FFF process is mainly used to create 3D parts made of thermoplastic polymers, and complex physical phenomena such as melt flow, heat transfer, solidification, crystallization, etc. are involved in the FFF process. Different techniques have been developed and employed to analyze these phenomena, including experimental, analytical, numerical, and finite element analysis (FEA). This study specifically aims to provide a comprehensive review of the developed numerical models and simulation tools used to analyze melt flow behavior, heat transfer, crystallization and solidification kinetics, structural analysis, and the material characterization of polymeric components in the FFF process. The strengths and weaknesses of these numerical models are discussed, simplifications and assumptions are highlighted, and an outlook on future work in the numerical modeling and FE simulation of FFF is provided.