Abstract
Fused Deposition Modeling (FDM) is a 3D printing process where thermoplastic
materials are deposited layer by layer through an extrusion nozzle. One of the main advantages of
an FDM process is that any complex shape geometry can be printed directly from a CAD model.
However, the process also shows disadvantages such as air-gap, porosity, weak inter-layer bonding
due to thermal gradient, which lead to unwanted print failure at the time out of the machine or under
in-service conditions. Therefore, it would be beneficial to model and predict possible print failures
early at part and process design stages in order to reduce the scrap rate and decrease product
development cycle.