Residual Stresses and Distortion in Material Extrusion Additive Manufacturing of Reinforced Thermoplastic Composites: A Review

Material extrusion additive manufacturing, commonly implemented as fused deposition modeling (FDM) or fused filament fabrication (FFF), has evolved into a manufacturing route for reinforced thermoplastic composites, including particle-filled, short-fiber-reinforced, and continuous-fiber-reinforced systems. The process is governed by a layer-by-layer thermal cycle. Deposited roads cool rapidly, are repeatedly reheated by subsequent material deposition, and finally cool non-uniformly as part of the growing structure. This thermal history generates residual-stress that may cause warpage, build–platform detachment, delamination, dimensional error, and reduced mechanical performance. This review synthesizes residual-stress formation, measurement, modeling, parameter effects, and mitigation in material-extruded reinforced thermoplastic composites, with emphasis on short and continuous-fiber systems. Stress formation is discussed in terms of constrained thermal contraction, crystallization shrinkage, anisotropic stiffness, fiber-constrained deformation, porosity, and fiber–matrix thermal expansion mismatch. Experimental methods, including hole drilling, layer removal, curvature methods, embedded fiber Bragg gratings, digital image correlation, photoelasticity, and warpage metrology, are critically compared for anisotropic and porous printed composites. Analytical and numerical models are reviewed from layerwise shrinkage formulations to crystallization-coupled thermo-viscoelastic finite element simulations. Finally, mitigation strategies are evaluated. A central conclusion is that reinforcement can suppress visible distortion while increasing stress retained in a stiffer structure. Therefore, warpage alone is not a sufficient residual stress metric.