A Review of the Fused Deposition Modeling (FDM) Process: An Integrated Analysis of Materials, Manufacturing Parameters, Mechanical Properties, Defect Formation, and Quality Assessment

Author

Marius-Valentin Drăgoi, Cozmin Adrian Cristoiu


Abstract

 Fused Deposition Modeling (FDM) is widely used in polymer additive manufacturing, although printed component performance depends on several interacting material and process-related factors. This review examines 60 selected publications from 2022 to 2026, covering thermoplastic materials, manufacturing parameters, mechanical properties, defect formation, and quality assessment. The literature is organized into an integrated, process-oriented framework connecting material selection and printing conditions with interlayer bonding, structural performance, manufacturing defects, and quality verification. Five comparative tables and two conceptual schemes summarize material characteristics, defect mechanisms, inspection methods, and optimization trade-offs. The analysis indicates that printing parameters influence mechanical performance and manufacturing quality differently across conventional, reinforced, flexible, and recycled polymers. Conventional testing remains essential, while sensor-based monitoring, computer vision, and machine learning offer complementary opportunities for defect detection and process refinement. The review also highlights limitations associated with experimental comparability, process reproducibility, internal defect characterization, and the generalization of intelligent monitoring approaches. Future research directions include standardized testing, multimodal quality assessment, fatigue characterization, and material-specific optimization. The resulting synthesis provides a structured reference for evaluating and improving FDM manufacturing processes.



Keywords

Fused Deposition Modeling; Fused Filament Fabrication; Additive Manufacturing; Manufacturing Parameters; Mechanical Properties; Defect Formation; Quality Assessment; Process Optimization.



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References


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