Fused Deposition Modeling Process Research Articles

Artificial Neural Network for Benchmarking the Dimensional Accuracy of the PLA Fused Flament Fabrication Process

Fused Deposition Modeling (FDM) is an additive manufacturing technique that uses a 3D printer to extrude molten filament through a nozzle, which moves along the X, Y, and Z axes to create parts with the desired geometry. FDM offers numerous advantages, especially for producing parts with complex shapes, due to its ability to enable rapid and cost-effective manufacturing compared to traditional methods. This study implemented an Artificial Neural Network (ANN) to optimize process parameters aimed at minimizing dimensional inaccuracies in the FDM process. Key parameters considered for optimization included the number of shells, infill percentage, and nozzle temperature. The ANN utilized three algorithms: Scaled Conjugate Gradient, Bayesian Regularization, and Levenberg-Marquardt. Model performance was evaluated based on dimensional deviations along the X and Y axes, with a hidden layer of 25 neurons. Among the algorithms, Scaled Conjugate Gradient provided the most accurate results in minimizing dimensional errors.

Development of a Robot-Assisted Fused Deposition Modeling Process for Enhanced Additive Manufacturing

<div>This work aims to define a novel integration of 6 DOF robots with an extrusion-based 3D printing framework that strengthens the possibility of implementing control and simulation of the system in multiple degrees of freedom. Polylactic acid (PLA) is used as an extrusion material for testing, which is a thermoplastic that is biodegradable and is derived from natural lactic acid found in corn, maize, and the like. To execute the proposed framework a virtual working station for the robot was created in RoboDK. RoboDK interprets G-code from the slicing (Slic3r) software. Further analysis and experiments were performed by FANUC 2000ia 165F Industrial Robot. Different tests were performed to check the dimensional accuracy of the parts (rectangle and cylindrical). When the robot operated at 20% of its maximum speed, a bulginess was observed in the cylindrical part, causing the radius to increase from 1 cm to 1.27 cm and resulting in a thickness variation of 0.27 cm at the bulginess location. However, after optimizing the speed at 35% of its maximum speed, 100% dimensional accuracy was achieved. The integration resulted in collision-free robot and extrusion movement, flexibility, capability of making large parts, and enhanced dimensional accuracy.</div>

Enhanced Photovoltaic Efficiency through 3D-Printed COC/Al₂O₃ Anti-Reflective Coversheets

In the past few years, there has been a considerable growth in the utilization of solar cells to produce electrical power to fulfil the growing worldwide energy demands. An optical loss is a crucial factor that impacts the performance of the photovoltaic conversion process. This loss occurs when incoming sunlight is reflected back on the outer layer of the photovoltaic cells. The application of antireflective materials on the photovoltaic substrates can enhance the absorption of sunlight and minimize the reflection. Currently, there is no ideal anti-reflective coating for solar cells that can allow the transmission of sunlight without any reflection. In this research, a transparent cyclic-olefin-copolymer (COC) was used to fabricate anti-reflection (AR) coversheet by fused deposition modelling process (3D printing). Further, the aluminium oxide Al2O3 powder was added at the proportions of 1wt%, 2wt%, 3wt%, and 4wt% to the COC polymer to increase the anti-reflection characteristics. The structural, morphological, mechanical (tear strength), electrical and temperature characteristics were studied. The performance of COC with aluminium oxide (COCA) coversheets was evaluated, and the findings revealed a considerable increment in power conversion efficiency (PCE) of 17.21% (sunlight exposure) and 18.34% (neodymium light) for COCA3 coversheets. As seen, the COCA3 sample exhibit lower electrical resistance of 3.88 ×10-3 Ω cm, carrier concentration (36.91×1020 cm-3) and higher hall mobility (13.67 cm2/Vs). The findings from the investigations demonstrated that the utilization of COC with Al2O3 powder (COCA) can be a suitable antireflective coversheet material for boosting the performance of polycrystalline silicon photovoltaic cells.

Fiberglass Reinforcement of Additively Manufactured Polymeric Specimens via FDM Process

This scientific paper focuses on the utilization of fiberglass reinforcement in the manufacturing of additively manufactured polymeric specimens via the Fused Deposition Modelling (FDM) process. The study explores the potential of fiberglass for enhancing the mechanical properties of FDM printed parts. The research investigates the effects of fiberglass reinforcement on the mechanical characteristics of FDM printed specimens. Fiberglass, known for its unique structural properties, is incorporated into the polymer matrix during the printing process. The study evaluates the influence of varying fiberglass content, fiber orientation, and processing parameters on the tensile strength of the resulting composite specimens. The mechanical properties of the fiberglass-reinforced FDM printed specimens are assessed through experimental testing, including tensile tests. The results are compared to those of unreinforced FDM printed specimens to identify the improvements achieved through the addition of glass fibers. The paper discusses the potential benefits of incorporating fiberglass into FDM printed parts.

Evaluation of Mechanical Properties of ABS-like Resin for Stereolithography Versus ABS for Fused Deposition Modeling in Three-Dimensional Printing Applications for Odontology.

This study investigates the differences in mechanical properties between acrylonitrile butadiene styrene (ABS) samples produced using fused deposition modeling (FDM) and stereolithography (SLA) using ABS filaments and ABS-like resin, respectively. The central question is to determine how these distinct printing techniques affect the properties of ABS and ABS-like resin and which method delivers superior performance for specific applications, particularly in dental treatments. The evaluation methods used in this study included Shore D hardness, accelerated aging, tensile testing, Izod impact testing, flexural resistance measured by a 3-point bending test, and compression testing. Poisson's ratio was also assessed, along with microstructure characterization, density measurement, confocal microscopy, dilatometry, wettability, Fourier-transform infrared spectroscopy (FTIR), and nanoindentation. It was concluded that ABS has the same hardness in both manufacturing methods; however, the FDM process results in significantly superior mechanical properties compared to SLA. Microscopy demonstrates a more accurate sample geometry when fabricated with SLA. It is also concluded that printable ABS is suitable for applications in dentistry to fabricate models and surgical guides using the SLA and FDM methods, as well as facial protectors for sports using the FDM method.

Drilling parameter optimisation for three-dimensional prints of acrylonitrile butadiene styrene

Abstract Over the past decade, additive manufacturing has transformed the industry, leading to a range of innovative products. In this study, the acrylonitrile butadiene styrene specimen was produced using the fused deposition modeling process. To assess the effectiveness of additive manufacturing parts in final product development, it’s crucial to establish the optimal drilling process parameters to minimize thrust force and torque. The investigation utilized two different drill geometries. Drilling with an end mill resulted in a 24.22% reduction in thrust force and a 12.37% decrease in torque compared to using a twist drill. Additionally, factors such as orientation, infill density, feed rate, and drill geometry have a significant impact on drilling forces.

Energy-efficient FDM printing of sustainable polymers: Optimization strategies for material and process performance

The integration of sustainable polymers in fused deposition modeling (FDM) 3D printing offers a promising pathway toward reducing the environmental impact of additive manufacturing. However, the energy-intensive nature of FDM processes presents a significant challenge to the overall sustainability of this technology. In this study, we explore the use of bio-based and recycled polymers in FDM printing and develop optimization strategies to reduce energy consumption without compromising material and print performance. Our results demonstrate that by systematically optimizing key printing parameters such as extrusion temperature, print speed, and layer height it is possible to achieve up to 20% energy savings. Additionally, we find that novel material formulations and advanced thermal management techniques enhance the mechanical properties of printed objects by up to 15%, all while minimizing energy use. This research not only advances the field of sustainable 3D printing but also provides a framework for the development of next-generation materials and processes that align with the principles of a circular economy.

Comparison of energy absorption characteristics of novel lattice structures inspired by Helleborus petticoat flower and fish scale pattern for different loading orientations

In the present work, arc-shaped, thin-strut-based structures were developed by taking inspiration from the cup shaped Helleborus petticoat flower and fish scale pattern. The designed structures have been additively manufactured with a fused deposition modeling process. In this work, one fish scale pattern inspired structure was developed and named FS structure, whereas two flower-inspired structures were developed and named FL4 and FL8 structures. The static compression tests were conducted to study stress-strain behavior of the proposed structures in two different orientations, viz. orientation:1 (along z-axis) and orientation:2 (along x-axis). Furthermore, the mechanical responses and energy absorption characteristics are comprehensively examined for the proposed structures in both orientations. The structures exhibited higher specific energy absorption (SEA) in orientation:1 compared to orientation:2. The increment in SEA is ∼29 % for FS, ∼298% for FL4, and ∼115% for FL8 structures in orientation:1 compared to orientation:2. Meanwhile, the proposed bio-inspired structures are capable of absorbing energies in the range of 0.06-0.47 MJ/m3, up to densification. Finally, SEA of proposed structures is compared with the SEA of other structures in the available literature.

Fabrication of PEI/CF composite parts with multi-angle reinforced mechanical properties by a micro-extrusion foaming FDM process

The combination of fused deposition modeling (FDM) and foaming technology enables the fabrication of complex hierarchical and lightweight parts. However, this approach is hindered by a reduction in the mechanical properties of final parts. To this end, with the aim of addressing the challenge of the fabrication of 3D-printed parts with enhanced mechanical and lightweight features, a micro-extrusion foaming FDM process using CO2 as a blowing agent was hereby established, and the carbon fiber (CF) was selected as a reinforcing filler. Compared to pure polyetherimide (PEI) parts, the longitudinal tensile strength of the PEI/CF parts with 5.0 wt% CF added increased by 30.3 %, while the interfacial bonding strength of PEI/CF-5.0 foamed parts increased by 86.3 % compared to the unfoamed parts. Furthermore, the PEI/CF-5.0 foamed parts, weighing only about 1.7 g, could bear a load of a 60 kg human body in multiple directions. Additionally, focusing on the filler orientation and the enhanced interdiffusion and entanglement of polymer chains at interfaces, the reinforcement mechanisms of the foamed parts fabricated by micro-extrusion foaming FDM process were discussed. The micro-extrusion foaming FDM process demonstrated the capability to produce lightweight parts with enhanced mechanical properties, making it a promising technology for applications in the aerospace and military industries.

Microhole Creation in FDM-Printed Sheet Polymers: A Punching Process Approach

Fused deposition modeling (FDM) 3D printing is one of the additive manufacturing processes that can make components with complex shapes, require no tools, are cheap, safe, and have minimal waste. Despite all the advantages of the FDM process, the inability of this technique to create holes on a micro scale can be a problem and limits its application. In this research, a combination of FDM and machining processes was carried out, where micro holes in FDM printed components were created using a punching process. The punching process is carried out by varying pressure and speed. Furthermore, the diameter of the hole and the quality of the sheared edge of the hole resulting from the punching process were evaluated through observation using an optical microscope. The results show that the holes resulting from the punching process have a better shape and diameter than the FDM process. Then, the analysis of the sheared edge from punching shows that pressure and speed significantly affect the surface quality of the resulting sheared edge, where the quality increases with increasing pressure and speed. In the end, the punching process was proven to create micro-scale holes in FDM-printed polymer, especially at minimum thickness.

Evaluation of Fused Deposition Modelling process parameters influence on the porosity of printed parts

Fused Deposition Modelling (FDM) is an additive manufacturing technology that is rapidly gaining popularity due to its ability to produce complex shaped parts in a short time. However, parts produced by means of FDM have porosity that results from the printing process. The mechanical properties of printed parts depend on the FDM process parameters and porosity. This study investigates the effect of FDM process parameters on the porosity of FDM parts. The results of the study show that properly selected FDM process parameters can significantly minimize the percentage of part porosity. The effect of FDM process parameters on porosity was determined by analyzing nine process variables: layer height, extrusion temperature, printing speed, extrusion multiplier, bed temperature, infill pattern, deposited strand width, number of shells, number of solid top and bottom layers. The percentage of samples porosity was measured by means of the hydrostatic weighing method. Using the analysis of variance, statistically significant factors and their combinations affecting the percentage of parts porosity were determined. It was shown that the extrusion multiplier had the greatest influence on the percentage of parts porosity. A significant contribution to the formation of porosity was made by the infill pattern, layer heights, printing speed, number of shells, number of solid top and bottom layers and their interaction. A regression model has been developed that allows predicting the porosity of parts achieved by different combinations of FDM process parameters.

Characterization of Thermal Expansion Coefficient of 3D Printing Polymeric Materials Using Fiber Bragg Grating Sensors.

This work aims at the determination of the coefficient of thermal expansion (CTE) of parts manufactured through the Fused Deposition Modeling process, employing fiber Bragg grating (FBG) sensors. Pure thermoplastic and composite specimens were built using different commercially available filament materials, including acrylonitrile butadiene styrene, polylactic acid, polyamide, polyether-block-amide (PEBA) and chopped carbon fiber-reinforced polyamide (CF-PA) composite. During the building process, the FBGs were embedded into the middle-plane of the test specimens, featuring 0° and 90° raster printing orientations. The samples were then subjected to thermal loading for measuring the thermally induced strains as a function of applied temperature and, consequently, the test samples' CTE and glass transition temperature (Tg) based on the recorded FBG wavelengths. Additionally, the integrated FBGs were used for the characterization of the residual strain magnitudes both at the end of the 3D printing process and at the end of each of the two consecutively applied thermal cycles. The results indicate that, among all tested materials, the CF-PA/0° specimens exhibited the lowest CTE value of 14 × 10-6/°C. The PEBA material was proven to have the most isotropic thermal response for both examined raster orientations, 0° and 90°, with CTE values of 117 × 10-6/°C and 108 × 10-6/°C, respectively, while similar residual strains were also calculated in both printing orientations. It is presented that the followed FBG-based methodology is proven to be an excellent alternative experimental technique for the CTE characterization of materials used in 3D printing.

Additive Manufacturing of Waste Electrical and Electronic Equipment (WEEE) Produced From Acrylonitrile Butadiene Styrene (ABS)

Objective: To evaluate the feasibility of producing recycled acrylonitrile-butadiene-styrene (r-ABS) filaments from waste electrical and electronic equipment (W EEE) casings, specifically discarded monitors and televisions, and to compare their properties with those of virgin ABS. Theoretical Framework: The research was based on a literature review of additive manufacturing, WEEE recycling, and the thermal, mechanical, rheological, and microscopic characterizations of recycled polymers, with an emphasis on fused deposition modeling (FDM). Method: WEEE casings were collected and mechanically recycled to produce r-ABS filaments. These filaments were characterized and compared with virgin ABS filaments using infrared spectroscopy (FTIR), thermal analyses (TGA and DSC), rheological, mechanical, and microscopic evaluations. Results and Conclusion: The results indicated that r-ABS filaments exhibit properties comparable to those of virgin ABS. FTIR analysis revealed the presence of the main functional groups of ABS in the recycled samples. Thermal analysis showed similar behavior between the recycled and virgin materials, with a single thermal decomposition event. Rheological analysis demonstrated that r-ABS possesses viscoelastic properties suitable for the FDM process, and mechanical characterization showed that r-ABS exhibited tensile strength close to virgin ABS. Microscopic analysis revealed good layer adhesion and a low number of voids, factors that contribute to the quality of the printed objects. Research Implications: This study contributes to the valorization of polymeric waste, promoting the use of recycled materials in additive manufacturing processes, which can benefit both the environment and the 3D printing industry. Originality/Value: The research addresses a topic still underexplored in the literature, especially concerning the recycling of WEEE casings for the production of ABS filaments.

Assessment on the influence of FDM process parameters on the mechanical properties of PLA samples

Abstract The manufacturing of functional parts from the fused deposition modeling 3D printer is limited due to poor mechanical properties, low surface finish, and huge production time. During 3D printing of prototypes, the time consumption of printing and mechanical properties of the model is directly proportional. The fused deposition modeling process parameters significantly impact the quality of printed parts. The prime objective of this research is to optimize the process parameters of a 3D printing machine (wall thickness, infill percentage, infill pattern, and infill speed) using polylactic acid material to enhance the mechanical properties with less printing time of the 3D printing model. The ultimate tensile strength and elongation of the 3D printed samples are used to evaluate the mechanical properties of the various slicing process parameters as per the standards. From the results, it is evident that the mechanical properties of the 3D printed materials increased significantly. The magnitude of ultimate tensile strength is reported as 39.972 MPa with a printing time of 28 min. From close observation, it is evident that lower infill speeds with gyroid infill pattern produce the highest ultimate tensile strength of all combinations. Also, optimal results are derived at higher wall thickness and higher infill percentage. In addition to that, finite element analysis was carried out for different infill percentages of the specimen to validate the actual result.

Comparative Study of Mechanical Properties and Microstructure Between Conventional and Infinite z-Axis Fused Deposition Modeling Printers

Additive Manufacturing (AM) has emerged as a critical technology in shaping manufacturing strategies, offering versatility and efficiency in designing complex structural components. Extensive literature exists on small- to mid-sized product production. However, a significant knowledge gap exists in manufacturing elongated products, such as wind turbine blades and constructional beams. Current AM technology faces limitations in this context, primarily due to the constraints imposed by the conventional 90-degree nozzle head and limited bed space. This study introduces an innovative AM approach called Infinite z-Axis Printing. This novel technique utilizes a belt-driven heated bed and a 45-degree nozzle head to 3D print objects of infinite length. The study compares this groundbreaking approach and the traditional 90-degree nozzle head Fused Deposition Modeling (FDM) method and the associated results. The findings of this research demonstrate that the Infinite z-Axis Printing methodology yields a significant improvement of up to 20% in tensile and compressive strength compared to the currently used FDM process. This advancement can potentially revolutionize on-site operations by enabling the efficient production of elongated structural components, thus contributing significantly to the construction and renewable energy sectors.

A new strategy for manufacturing, modeling, and optimization of 3D printed polylactide based on multiple nonlinear neuro regression analysis and stochastic optimization methods

Although there are many studies related to design, modeling, and optimization of fused deposition modeling (FDM) process parameters in the literature, the absence of a systematic approach to increase the reliability of model selection and optimization results is an important shortcoming that must be addressed. To make up for this deficiency, a new strategy was proposed to obtain desired quality on mechanical properties by adjusting FDM process parameters. This attempt involves manufacturing, modeling, and optimization point of view. The D-optimal method was employed to form experiment set, including process parameters. A hybrid approach neuro regression combining artificial neural network (ANN) and regression analysis together was used for modeling of FDM process. The most significant advantage of the neuro-regression approach compared to ANN is that the mathematical models can be used directly without needing any transformation. This is not possible in neural networks and, therefore, significantly limits and complicates the use of models obtained using ANN. The present study aims at optimization of the FDM process parameters, including infill density, infill pattern, layer thickness, and print speed on ultimate strength, fracture strength, and fracture strain for polylactide (PLA). In this regard, modified versions of the optimization algorithms Differential Evolution, Nelder Mead, and Simulated Annealing were used to find the best or elite designs. Linear or nonlinear models consisting of polynomial, trigonometric, and logarithmic expressions and their hybrid forms were employed to define the strength and strain behavior of PLA. It is concluded that (a) implementations of the optimization algorithms provide a 19% improving the minimum strain value if it is compared with the experimental results, (b) infill pattern types ( x2) were found as honeycomb, triangle, and cubic for the designs in terms of maximum fracture strength, minimum strain, and maximum ultimate tensile strength respectively, (c) many alternatives near optimum local designs could be obtained based on Nelder Mead algorithm for fracture strength and ultimate strength parameters. Thus, this allows work in a wide range of applications without depending on a single result for production.

Enhancing 3D Printing Copper-PLA Composite Fabrication via Fused Deposition Modeling through Statistical Process Parameter Study.

The rapid advancement of additive manufacturing (AM) technologies has provided new avenues for creating three-dimensional (3D) parts with intricate geometries. Fused Deposition Modeling (FDM) is a prominent technology in this domain, involving the layer-by-layer fabrication of objects by extruding a filament comprising a blend of polymer and metal powder. This study focuses on the FDM process using a filament of Copper-Polylactic Acid (Cu-PLA) composite, which capitalizes on the advantageous properties of copper (high electrical and thermal conductivity, corrosion resistance) combined with the easily processable thermoplastic PLA material. The research delves into the impact of FDM process parameters, specifically, infill percentage (IP), infill pattern (P), and layer thickness (LT) on the maximum failure load (N), percentage of elongation at break, and weight of Cu-PLA composite filament-based parts. The study employs the response surface method (RSM) with Design-Expert V11 software. The selected parameters include infill percentage at five levels (10, 20, 30, 40, and 50%), fill patterns at five levels (Grid, Triangle, Tri-Hexagonal, Cubic-Subdivision, and Lines), and layer thickness at five levels (0.1, 0.2, 0.3, 0.4, and 0.5 mm). Also, the optimal factor values were obtained. The findings highlight that layer thickness and infill percentage significantly influence the weight of the samples, with an observed increase as these parameters are raised. Additionally, an increase in layer thickness and infill percentage corresponds to a higher maximum failure load in the specimens. The peak maximum failure load (230 N) is achieved at a 0.5 mm layer thickness and Tri-Hexagonal pattern. As the infill percentage changes from 10% to 50%, the percentage of elongation at break decreases. The maximum percentage of elongation at break is attained with a 20% infill percentage, 0.2 mm layer thickness, and 0.5 Cubic-Subdivision pattern. Using a multi-objective response optimization, the layer thickness of 0.152 mm, an infill percentage of 32.909%, and a Grid infill pattern was found to be the best configuration.

RSM-BASED STATISTICAL APPROACH TO ENHANCE THE COMPRESSIVE PERFORMANCE OF ABS P400 PARTS FABRICATED VIA FDM TECHNOLOGY

This research investigates the performance of ABS P400 parts under compressive loading. These ABS P400 parts are fabricated by fused deposition modeling (FDM) process using omnidirectional printing. The effects of three critical parameters, raster angle (A), air gap (B), and raster width (C), each at three different levels, were analyzed on three different performance measures, i.e. total deformation up to failure ([Formula: see text]) measured in %, maximum energy ([Formula: see text]) in MJ/m3 and break energy ([Formula: see text]) in MJ/m3. Results of experimentations were analyzed using analysis of variance (ANOVA), perturbation curve and 3D surface plots. The research established the anisotropic nature, durability and less brittleness of the FDM fabricated ABSP400 part, which leads to lower strength and also influence the energy absorbing behavior while deformation under compression. Complex relationships were exhibited between the chosen parameters and studied measures. It was also observed that [Formula: see text] is noticeable due to less brittleness of ABS P400 however, [Formula: see text] and [Formula: see text] vary in a contradictory fashion with changes in process parameters. The models were validated using normality plots. Multi-objective optimization was done using the desirability approach to determine the optimal combination of FDM process parameters for optimum responses. The desirability result showed that the optimized input parameter is [Formula: see text][Formula: see text]mm, and [Formula: see text][Formula: see text]mm which yield maximized optimum responses as [Formula: see text]%, [Formula: see text][Formula: see text]MJ/m3, and [Formula: see text][Formula: see text]MJ/m3. The work not only reflects the effect of three FDM parameters on the total deformation up to failure ([Formula: see text] in %) but, in addition, energy absorption behavior of FDM parts under compression is also investigated. The study on the behavior of energy at ultimate stress or ultimate load and breaking stress or breaking load were rarely investigated in earlier research which reflects the novelty of our research.

A systematic review of the process parameters, mechanical characteristics and applications of polyether ether ketone (PEEK) and its composites by additive manufacturing

Abstract Additive manufacturing (AM) provides an innovative and reliable method of developing medical products with anatomically relevant geometry and mechanical performance, underscoring its significant potential in the medical field. The design of fused deposition modelling (FDM) parameters has a significant impact on the characteristics of the product fabricated utilizing FDM. Numerous studies have assessed the impact of various FDM process parameters on enhancing the print quality attributes of manufactured components, such as mechanical characteristics, production times, dimensional accuracy, and surface finish. Because of the complex features of the FDM process and the contradicting process parameters, the advancement has been slow and poorly coordinated. This work intends to provide a complete review of recent research on PEEK and CF-PEEK printed parts, where the effect of process factors on tensile strength has been described. Furthermore, PEEK, with its potential applications in medical, aerospace, and chemical sectors, serves as an inspiring material for future innovations, offering a promising outlook.

Development of isotactic polypropylene‐based 3D printing materials with good dimensional accuracy and excellent impact properties

AbstractThe main challenge of fused deposition modeling (FDM) is the limited variety of commercially available semicrystalline polymer materials. Isotactic polypropylene (iPP), with a fast crystallization rate and high crystallinity, tends to undergo extensive volumetric shrinkage during the FDM process, further inducing severe deformation and poor dimensional accuracy in 3D‐printed parts. This study aims to develop desirable iPP‐based materials for the FDM technique through physically blending iPP and thermoplastic polyester elastomer (TPEE). TPEE retards the nonisothermal crystallization ability of iPP, as indicated by the significant decrease in crystallinity (Xc) from 47.7% for neat iPP to 28.5% for the iPP blend at a weight ratio of 30/70. The suppressed crystallization behavior accounts for a drastic decrease in the warpage degree of the 3D‐printed parts. The greater the content of TPEE is, the lower warpage the 3D‐printed parts have. Additionally, the presence of TPEE slightly influences the shear viscosity of iPP. As a result, iPP blends exhibit excellent extrudability during a typical FDM process. TPEE also enhances the impact strength of 3D‐printed parts by 168% compared to that of injection‐molded iPP. Taken together, the iPP blends developed in this work are promising FDM feedstock materials with good dimensional accuracy and excellent impact strength.