Date of Award


Publication Type

Master Thesis

Degree Name



Industrial and Manufacturing Systems Engineering


Mechanical engineering, Materials science


Ruth Jill Urbanic




Parametric internal structures based on basic geometries present an easy and reliable way to reduce the internal solid volume fraction of the fused deposition modeling (FDM) rapid prototype (RP) part while guaranteeing the structural integrity of the physical model. This would reduce the material costs, which may be significant for large components. The present research proposes a novel method that, based on multidisciplinary and experimental approach, characterizes the mechanical behavior and predicts the material use and build time with the intention of optimizing the strength while reducing costs. The proposed approach comprises a set of physical and virtual experimentation techniques that merge to provide a comprehensive analytical resource. Results indicate that the FEA method represents accurately the mechanical behavior of the RP parts whereas the statistical analysis provides insight. This unique approach serves as a basis to understand the work performed in similar studies and leaves a number of possible topics that, once explored, will have a strong impact on the optimization of not only the FDM process, but the entire Rapid Prototyping industry.