In this paper, the fatigue response of fused filament fabrication (FFF) Acrylonitrile butadiene styrene (ABS) parts is studied. Different building parameters (layer height, nozzle diameter, infill density, and printing speed) were chosen to study their influence on the lifespan of cylindrical specimens according to a design of experiments (DOE) using the Taguchi methodology. The same DOE was applied on two different specimen sets using two different infill patterns—rectilinear and honeycomb. The results show that the infill density is the most important parameter for both of the studied patterns. The specimens manufactured with the honeycomb pattern show longer lifespans. The best parameter set associated to that infill was chosen for a second experimental phase, in which the specimens were tested under different maximum bending stresses so as to construct the Wöhler curve associated with this 3D printing configuration. The results of this study are useful to design and manufacture ABS end-use parts that are expected to work under oscillating periodic loads.

Additive Manufacturing (AM), commonly known as 3D printing, has gained significant traction across various industries due to its versatility and customization potential. However, the process remains time-consuming, with print durations ranging from hours to days depending on the complexity and size of the object. In many cases, errors occur due to object misalignment, material stringing due to nozzle overflow, and filament blockages, which can lead to complete print failures. Such errors often go undetected for extended periods, resulting in substantial losses of time and material. This study explores the implementation of traditional computer vision, image processing, and machine learning techniques to enable real-time error detection, specifically focusing on stringing-related anomalies. To address data scarcity in training machine learning models, we also release a new dataset and improve upon the results achieved by the Obico server model, one of the most prominent tools for stringing detection. Our contributions aim to enhance process reliability, reduce material wastage, and optimize time efficiency in AM workflows.

In this paper, the fatigue response of Fused Filament Fabrication (FFF) Acrylonitrile butadiene styrene (ABS) parts is studied. Different building parameters (layer height, nozzle diameter, infill density, and printing speed) were chosen to study their influence on the lifespan of cylindrical specimens according to a design of experiments (DOE) using the Taguchi methodology. The same DOE was applied on two different specimen sets using two different infill patterns: rectilinear and honeycomb. The results show that infill density is the most important parameter for both studied patterns. The specimens manufactured with the honeycomb pattern show longer lifespans. The best parameter set associated to that infill was chosen for a second experimental phase, in which the specimens were tested under different maximum bending stresses to construct the Wöhler curve associated to this 3D printing configuration. The results of this study are useful to design and manufacture ABS end-use parts that are expected to work under oscillating periodic loads.