Optimization of Ultem 1010 Fused Depositon Modeling Specimens for Flexural Behavior


Fused Deposition Modeling (FDM) process, as one of most widely used additive manufacturing methods, provides capabilities of fabricating complicated shapes through extrusion of plastics onto a print surface in a layer-by-layer structure. The flexural behavior of FDM parts are critical for the evaluation and optimization of both material and process. This study focuses on the performance of FDM solid and sparse-build specimens. Ultem 1010 is used to manufacture both solid and sparse-build specimens. Solid-build coupons for flexure tests are manufactured with varying build parameters through the application of a full-factorial design of experiments (DOE). Varying build parameters consist of raster angle and build orientation while air gap, raster width, and contour width are held constant. Results from the experimental study include flexure properties such as yield strength, modulus, specific strength, and specific modulus as well as analysis of the effect of change in build parameters on material properties. From the DOE study, several sparse-build coupons were fabricated for simulation validation. A three-dimensional nonlinear finite element model was built to simulate the mechanical behavior of the FDM parts. The sparse-build FDM parts under flexure were simulated based on this developed model. Thermo-mechanical simulation results show that predictions of finite element simulation are in good agreement with experimental data. This simulation can be further extended to other complicated FDM parts.

Meeting Name

Composites and Advanced Materials Expo 2017, CAMX 2017 (2017: Dec. 11-14, Orlando, FL)


Mechanical and Aerospace Engineering

Research Center/Lab(s)

Center for High Performance Computing Research

Keywords and Phrases

3D printers; Deposition; Design of experiments; Thermomechanical treatment; Finite element simulations; Fused deposition modeling; Layer by layer structure; Mechanical behavior; Science and Technology; Simulation validation; Thermomechanical simulation; Three-dimensional nonlinear finite element model; Finite element method

Document Type

Article - Conference proceedings

Document Version


File Type





© 2017 The Composites and Advanced Materials Expo (CAMX), All rights reserved.

Publication Date

01 Dec 2017

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