Design methodology for fused filament fabrication with process chain: framework, database, design rule, methodology and study of case

Purpose Additive manufacturing (AM) is valued for flexibility and low cost, but fused filament fabrication (FFF) and fused deposition modeling (FDM) face issues with finish, tolerances and strength. Combining conventional manufacturing with FFF/FDM addresses these gaps, but design for additive manufacturing (DFAM) approaches are limited. This study develops a methodology to enhance FFF product quality by integrating DFAM principles with process chains (CP). Design/methodology/approach Using case studies and DFAM literature, a database was created to analyze common requirements and methods, establishing general design rules. These rules were applied to a case study to demonstrate improvements. Findings DFAM approaches for FFF in CP are rare. Combining FFF with other processes improves quality (tolerances, surface finish, strength, and others) but raises cost and time. This methodology balances FFF’s cost benefits with enhanced product properties. Originality/value Unlike studies focusing on hybrid processes or machinery, this methodology uniquely integrates FFF with other processes, offering an innovative, low-cost solution to overcome FFF limitations.