Three-Dimensional Numerical Modeling of Fused Deposition Modeling (FDM)

A detailed computational model of the FDM extrusion and deposition process is developed and validated against experimental data. Capturing thermal gradients, polymer flow behaviour, layer adhesion mechanics, and residual stress distribution, the simulations accurately predict dimensional accuracy and mechanical strength, enabling parameter optimisation without extensive physical trial-and-error — a significant advance for structural AM applications.