Cited by 7Additive Manufacturing and 3D Printing TechnologiesCellular and Composite StructuresAdditive Manufacturing Materials and Processes

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A review of design and fabrication strategies for thermoplastic lightweight thin-walled stiffened shells and lattice structures utilizing fused-filament fabrication (FFF)

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Ahmed, Rakin, Dola, Israt Sharmin, Ahmed, Sakib, Rahman, Md Mahmudur, Shanto, Tanvir Ahmed, Taylor, Robert·2026·The International Journal of Advanced Manufacturing Technology

DOI 10.1007/s00170-026-18078-6

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Abstract

The demand for lightweight and mechanically reliable structures has motivated increased interest in Additive Manufacturing (AM), particularly Fused Filament Fabrication (FFF), while underscoring the importance of an integrated understanding of the design-to-fabrication workflow. While numerous studies have focused on individual aspects of the FFF process in fabrication of such structures, detailed review linking design strategies, optimization techniques, and manufacturing challenges are scarce. This work addresses that gap by reviewing current strategies for designing and fabricating lightweight structures using FFF. First, it investigates sophisticated design and optimization strategies, consisting of Design for Additive Manufacturing (DfAM) concepts and Topology Optimization (TO) techniques specifically adapted for thin-walled and lattice structures. The limitations of traditional CAD tools are extensively investigated along with a summary of major manufacturing challenges. The review combines multidisciplinary insights to create an integrated understanding for generating structurally efficient and reliable FFF components. It concludes by outlining prospective future research avenues, including artificial intelligence–driven process control and digital twins for predictive modeling. This work offers a detailed resource for researchers and practitioners aiming to address existing limitations and drive FFF towards resilient next-generation lightweight systems.

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The Evolution of Thermoplastic Raw Materials in High-Speed FFF/FDM 3D Printing Era: Challenges and Opportunities
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Additive manufacturing of compliance optimized variable stiffness composites through short fiber alignment along curvilinear paths
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Unveiling the optimization process of physics informed neural networks: How accurate and competitive can PINNs be?
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Additive manufacturing and characterization of high temperature thermoplastic blends for potential aerospace applications
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A review of AI for optimization of 3D printing of sustainable polymers and composites
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An Overview of Analytic Solid Modeling
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Design for Additive Manufacturing: Recent Innovations and Future Directions
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Topology optimization for additive manufacturing of CFRP structures
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Scientometric Analysis and Systematic Review of Multi-Material Additive Manufacturing of Polymers
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Experimental investigation and Taguchi optimization of FDM process parameters for the enhancement of tensile properties of Bi-layered printed PLA-ABS
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Design for Additive Manufacturing: Tool Review and a Case Study
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Effects of Infill Density, Wall Perimeter and Layer Height in Fabricating 3D Printing Products
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Additive Manufacturing-Enabled Advanced Design and Process Strategies for Multi-Functional Lattice Structures
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An Overview of Additive Manufacturing of Triply Periodic Minimal Surface (TPMS) Structures
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Effect of nozzle diameter on mechanical and geometric performance of 3D printed carbon fibre-reinforced composites manufactured by fused filament fabrication
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Perspective: Machine Learning in Design for 3D/4D Printing
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Determination of mechanical properties of FFF 3D printed material by assessing void volume fraction, cooling rate and residual thermal stresses
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Level set band method: A combination of density-based and level set methods for the topology optimization of continuums
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In-Process Monitoring of Temperature Evolution during Fused Filament Fabrication: A Journey from Numerical to Experimental Approaches
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Warpage Analysis and Control of Thin-Walled Structures Manufactured by Laser Powder Bed Fusion
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Optimization of FFF Process Parameters by Naked Mole-Rat Algorithms with Enhanced Exploration and Exploitation Capabilities
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Effects of Environmental Temperature and Humidity on the Geometry and Strength of Polycarbonate Specimens Prepared by Fused Filament Fabrication
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Patient-specific 3D-printed Splint for Mallet Finger Injury
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Inter-layer bonding characterisation between materials with different degrees of stiffness processed by fused filament fabrication
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An investigation of the influence of 3d printing parameters on the tensile strength of PLA material
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Prediction of Mechanical Properties for Carbon fiber/PLA Composite Lattice Structures Using Mathematical and ANFIS Models
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Orthotropic mechanical properties of PLA materials fabricated by fused deposition modeling
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Near support-free multi-directional 3D printing via global-optimal decomposition
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A genetic algorithm for topology optimization of area-to-point heat conduction problem
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Optimizing fused filament fabrication process parameters for quality enhancement of PA12 parts using numerical modeling and taguchi method
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Design optimisation for an additively manufactured automotive component
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Application of Numerical Modeling and Finite Element Analysis in Fused Filament Fabrication: A Review
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Fused Filament Fabrication for Metallic Materials: A Brief Review
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Experimental testing and numerical analysis of FDM multi-cell inserts and hybrid structures
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The Extent of Interlayer Bond Strength during Fused Filament Fabrication of Nylon Copolymers: An Interplay between Thermal History and Crystalline Morphology
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A review of machine learning in additive manufacturing: design and process
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Enhancing Design for Additive Manufacturing Workflow: Optimization, Design and Simulation Tools
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Light-weight shape and topology optimization with hybrid deposition path planning for FDM parts
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Improved print quality in fused filament fabrication through localized dispensing of hot air around the deposited filament
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Printing polymer blends through in situ active mixing during fused filament fabrication
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The influence of porosity, crystallinity and interlayer adhesion on the tensile strength of 3D printed polylactic acid (PLA)
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AI-Driven Innovations in 3D Printing: Optimization, Automation, and Intelligent Control
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Effect of in situ thermal treatment on interlayer adhesion of 3D printed polyetherimide (PEI) parts produced by fused deposition modeling (FDM)
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Influence of geometric defects on the compression behaviour of thin shell lattices fabricated by micro laser powder bed fusion
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Mathematical Modeling and Optimization of Fused Filament Fabrication (FFF) Process Parameters for Shape Deviation Control of Polyamide 6 Using Taguchi Method
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Manufacturing and Characterization of 3D Miniature Polymer Lattice Structures Using Fused Filament Fabrication
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Thermal cycling, microstructure and tensile performance of PLA-PHA polymer printed using fused deposition modelling technique
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Self-Support Topology Optimization With Horizontal Overhangs for Additive Manufacturing
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Topology optimization methods for additive manufacturing: a review
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How to Improve Sustainability in Fused Filament Fabrication (3D Printing) Research?
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Three-dimensional high resolution topology optimization considering additive manufacturing constraints
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Topology optimization with nozzle size restrictions for material extrusion-type additive manufacturing
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Strength Enhancement in Fused Filament Fabrication via the Isotropy Toolpath
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Review on structural optimization techniques for additively manufactured implantable medical devices
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Investigation of Dimensional Integrity and Surface Quality of Different Thin-Walled Geometric Parts Produced via Fused Deposition Modeling 3D Printing
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Investigation on the Crashworthiness Performance of Thin-Walled Multi-Cell PLA 3D-Printed Tubes: A Multi-Parameter Analysis
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Topology optimization of thin-walled structures with directional straight stiffeners
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Additive Manufacturing in Underwater Applications
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Post-Process Effects of Isothermal Annealing and Initially Applied Static Uniaxial Loading on the Ultimate Tensile Strength of Fused Filament Fabrication Parts
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Conception of Design Principles for Additive Manufacturing
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Jigs and Fixtures in Production: A Systematic Literature Review
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A Comprehensive Review of Fused Filament Fabrication: Numerical Modeling Approaches and Emerging Trends
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Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology
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Revolutionizing Automotive Design: The Impact of Additive Manufacturing
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Influence of Temperature on Interlayer Adhesion and Structural Integrity in Material Extrusion: A Comprehensive Review
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Penalty regulation of overhang in topology optimization for additive manufacturing
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Bi-directional evolutionary stress-based topology optimization of material nonlinear structures
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Multiscale optimization of additively manufactured graded non-stochastic and stochastic lattice structures
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A manufacturing cost analysis framework to evaluate machining and fused filament fabrication additive manufacturing approaches
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Parametric Shell Lattice with Tailored Mechanical Properties
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Evolution, Prospects, and Predicaments of Polymers in Marine Applications: A Potential Successor to Traditional Materials
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Additive manufacturing of stiff and strong structures by leveraging printing-induced strength anisotropy in topology optimization
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High performance realization of functionally graded materials based on integrated optimal design and additive manufacturing: A review
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Supportless Lattice Structure for Additive Manufacturing of Functional Products and the Evaluation of Its Mechanical Property at Variable Strain Rates
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On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review
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Orientation-Dependent Mechanical Behavior of 3D Printed Polylactic Acid Parts: An Experimental–Numerical Study
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Edge AI-Enabled Road Fixture Monitoring System
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A hybrid of genetic algorithm and particle swarm optimization for reducing material waste in extrusion-basedadditive manufacturing
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The Mechanical Properties of Thin-Walled Specimens Printed from a Bronze-Filled PLA-Based Composite Filament Using Fused Deposition Modelling
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Geometric Accuracy and Dimensional Precision in 3D Printing-Based Gear Manufacturing: A Study on Interchangeability and Forming Precision
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Research works printed but not linked: 17

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Digital Twin and Artificial Intelligence Framework for Real-Time Optimization of Honeycomb Panel Geometry and Mechanical Performance
Mohammed, D. F. (2026) · Al-Noor Journal of Engineering Management and Computer Science · doi:10.71229/wx7czg04
From CAD to CNC: A toolpath-driven framework for hybrid additive–subtractive manufacturing of polymers
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A review of carbon composite marine propellers
Niloy, R. S., & Prusty, B. G. (2026) · Composites Part B Engineering · doi:10.1016/j.compositesb.2026.114138
Material–topology interaction in the tensile behaviour of FDM-printed PLA and TPU lattices
Tzu-Hua, C., Kai-Ting, C., & Li, Y.-T. (2026) · The International Journal of Advanced Manufacturing Technology · doi:10.1007/s00170-026-19102-5
Design and Compressive Characterization of Developed Lattice Structures for Lightweight Applications: A Preliminary Study
Kim, S., Cho, K., Vu, T. H., Lee, S., & Park, S. J. (2026) · Materials · doi:10.3390/ma19194067

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Authors: Ahmed, R., Dola, I. S., Ahmed, S., Rahman, M. M., Shanto, T. A., & Taylor, R.
Affiliations: The University of Texas at Arlington (US)
Corresponding author: Taylor, Robert
ORCID: Dola, Israt Sharmin
Rahman, Md Mahmudur
Shanto, Tanvir Ahmed
Taylor, Robert
Venue: The International Journal of Advanced Manufacturing Technology
Publisher: Springer Science and Business Media LLC
Published: 2026-05-09
Volume: 144
Issue: 9-10
Pages: 6111-6158
ISSN: 0268-3768 (ISSN-L)
1433-3015
DOI: 10.1007/s00170-026-18078-6
OpenAlex: W7160706711
Cited by: 6
References: 326
Citations by year: 2026: 6
FWCI: 10.83
Type: journal article
Language: en
Open access: hybrid
doi.org
Licence: cc-by-nc-nd
creativecommons.org/licenses/by-nc-nd/4.0 (tdm)
creativecommons.org/licenses/by-nc-nd/4.0 (vor)
Locations: The International Journal of Advanced Manufacturing Technology (publishedVersion, cc-by-nc-nd)
Topics: Physical Sciences › Engineering › Industrial and Manufacturing Engineering › Additive Manufacturing and 3D Printing Technologies
Physical Sciences › Engineering › Mechanical Engineering › Cellular and Composite Structures
Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
Keywords: fused deposition modeling, lightweight structures, thin-walled structures, stiffened shells, lattice structures, design for additive manufacturing, topology optimization, production problems, digital twin, predictive modeling

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A review of design and fabrication strategies for thermoplastic lightweight thin-walled stiffened shells and lattice structures utilizing fused-filament fabrication (FFF)

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