This study presents a newly developed program that seamlessly converts G-code into formats compatible with Abaqus, enabling precise finite element simulations for FDM 3D printing. The tool operates on a two-pronged framework: a mathematical model incorporating key print parameters (layer thickness, extrusion temperature, print speed, and raster width) and a shape generator managing geometric parameters (fill density, pattern, and raster orientation). Initially, a predefined virtual section, based on predetermined dimensions, enhanced the correlation between experimental results and simulations. Subsequently, a corrected virtual section, derived from the mathematical model using the Box–Behnken methodology, improves accuracy, achieving a virtual thickness error of 1.06% and a width error of 8%. The model is validated through tensile testing of ASTM D638 specimens at 0°, 45°, and 90° orientations, using adaptive C3D4 mesh elements (0.35–0.6 mm). Results demonstrate that the corrected cross-section significantly improved simulation accuracy, reaching correlations above 95% in the elastic zone and 90% in the elastoplastic zone across all orientations. By optimizing the workflow from design to manufacturing, this program offers substantial benefits for the aerospace, medical, and automotive sectors, enhancing both the efficiency of the printing process and the reliability of simulations.

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.

This study investigates the mechanical properties and crack propagation behavior of 3D-printed Acrylonitrile Butadiene Styrene (ABS) by integrating numerical simulations with experimental tensile testing. Utilizing the eXtended Finite Element Method (XFEM) within the Abaqus software, the research examines the damage evolution in ABS specimens under Mode I loading, focusing on the influence of factors such as print orientation, infill density, and layer thickness on mechanical performance. The numerical model, validated through uniaxial tensile tests conducted at a rate of 10 mm/min on ABS specimens with an initial notch, accurately captures the crack propagation process, revealing a two-stage fracture evolution: an initial stable phase over the first 60% of the specimen’s lifetime, followed by rapid crack growth leading to structural failure. Three distinct phases of crack propagation velocity are identified: low velocity during initiation, a quasi-static intermediate phase, and a high-velocity unstable phase, correlating with the evolution of the stress intensity factor. The close agreement between numerical and experimental results underscores the reliability of XFEM for modeling crack behavior, providing critical insights into optimizing 3D printing parameters to enhance the mechanical properties, structural integrity, and durability of ABS components for diverse engineering applications.