Experimental calibration of a virtual raster section for high-accuracy FDM simulation in Abaqus cover art

Experimental calibration of a virtual raster section for high-accuracy FDM simulation in Abaqus

Experimental calibration of a virtual raster section for high-accuracy FDM simulation in Abaqus

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 This study presents an experimentally calibrated methodology to enhance the predictive accuracy of finite element simulations for Fused Deposition Modeling (FDM) parts in Abaqus by replacing idealized filament geometry with a physically accurate “corrected virtual raster section.” A Box-Behnken Design of Experiments (DoE) across 27 ABS specimens systematically quantifies how key printing parameters, layer thickness, raster width, extrusion temperature, and print speed, influence the true cross-sectional geometry of deposited filaments, as measured via Scanning Electron Microscopy (SEM). These data inform a predictive mathematical model that transforms the conventional circular filament shape into an experimentally grounded oval-rectangular profile, accurately capturing extrusion-induced flattening and lateral spreading. The calibrated virtual section is integrated into a custom Python-based tool that parses G-code toolpaths and sweeps the corrected geometry along deposition trajectories to generate high-fidelity, mesh-ready Abaqus models. The workflow is validated through tensile testing of ASTM D638 specimens printed at 0°, 45°, and 90° raster orientations (n=3 per orientation). Error analysis against the experimental mean demonstrates that the corrected model reduces simulation errors from catastrophic levels in the non-corrected approach (7–92% relative error, 2.5–19 MPa absolute) to engineering-grade precision (0.03–7% relative error, ≤1.3 MPa absolute). This workflow bridges G-code to physical behavior, enabling reliable simulation of FDM anisotropy.
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