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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

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Abstract

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.

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Acknowledgements

The authors would like to thank King Fahd University of Petroleum & Minerals for the financial support of this work. In addition, the authors would like to thank Interdisciplinary Research Center for Advanced Materials (INAM 2413), Rapid Prototyping and Reverse Engineering Lab as well as K.A. CARE Energy Research & Innovation Center at Dhahran, Saudi Arabia for their guidance and support.

Funding

This work was supported by King Fahd University of Petroleum & Minerals.

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Authors and Affiliations

  1. Department of Mechanical Engineering, King Fahd University of Petroleum & Minerals, Dhahran, 31261, Saudi Arabia

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

  2. Interdisciplinary Research Center for Advanced Materials, King Fahd University of Petroleum & Minerals, Dhahran, 31261, Saudi Arabia

    Abba A. Abubakar & Usman Ali

  3. Interdisciplinary Research Center for Industrial Nuclear Energy, King Fahd University of Petroleum & Minerals, Dhahran, 31261, Saudi Arabia

    Khaled Al-Athel

  4. The Interdisciplinary Research Center for Intelligent Manufacturing and Robotics, King Fahd University of Petroleum & Minerals, Dhahran, 31261, Saudi Arabia

    Jafar Albinmousa

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  1. Mosa Almutahhar
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Almutahhar, M., AlHajeri, A., Abubakar, A.A. et al. Experimental investigation and computational modeling of voids in fused filament fabrication parts using a novel analytical model and a porosity-dependent hardening function. Int J Adv Manuf Technol (2026). https://doi.org/10.1007/s00170-026-18280-6

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