{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,3,27]],"date-time":"2026-03-27T23:20:26Z","timestamp":1774653626728,"version":"3.50.1"},"reference-count":103,"publisher":"MDPI AG","issue":"12","license":[{"start":{"date-parts":[[2025,6,14]],"date-time":"2025-06-14T00:00:00Z","timestamp":1749859200000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"\u201c0049_NATUR_FAB_2_E-Fomento de la especializaci\u00f3n inteligente, transici\u00f3n industrial y emprendimiento a trav\u00e9s de nuevos materiales basados em recursos end\u00f3genos compatibles com tecnologias de fabricaci\u00f3n aditiva de gran formato\u201d"}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Applied Sciences"],"abstract":"<jats:p>Fused Filament Fabrication (FFF) has become a widely adopted additive manufacturing technology due to its cost-effectiveness, material versatility, and accessibility. However, optimizing process parameters, predicting material behavior, and ensuring structural reliability remain major challenges. This review analyzes state-of-the-art computational methods used in FFF, which are categorized into four main areas: melt flow dynamics, cooling and solidification, thermal\u2013mechanical behavior, and material property characterization. Notably, the integration of Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) has led to improved predictions of key phenomena, such as filament deformation, residual stresses, and temperature gradients. The growing use of fiber-reinforced filaments has further enhanced mechanical performance; however, this also introduces added complexity due to filler orientation effects and interlayer adhesion issues. A critical limitation across existing studies is the lack of standardized experimental validation methods, which hinders model comparability and reproducibility. This review highlights the need for unified testing protocols, more accurate multi-physics simulations, and the integration of AI-based process monitoring to bridge the gap between numerical predictions and real-world performance. Addressing these gaps will be essential to advancing FFF as a precise and scalable manufacturing platform.<\/jats:p>","DOI":"10.3390\/app15126696","type":"journal-article","created":{"date-parts":[[2025,6,16]],"date-time":"2025-06-16T10:47:22Z","timestamp":1750070842000},"page":"6696","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":6,"title":["A Comprehensive Review of Fused Filament Fabrication: Numerical Modeling Approaches and Emerging Trends"],"prefix":"10.3390","volume":"15","author":[{"given":"Maria","family":"Enriconi","sequence":"first","affiliation":[{"name":"Mechanical Engineering Department, Instituto Polit\u00e9cnico de Bragan\u00e7a, Campus de Santa Apol\u00f3nia, 5300-253 Bragan\u00e7a, Portugal"},{"name":"Campus Curitiba, Universidade Tecnol\u00f3gica Federal do Paran\u00e1, R. Dep. Heitor Alencar Furtado, 5000-Cidade Industrial de Curitiba, Curitiba 81280-340, PR, Brazil"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-5499-0738","authenticated-orcid":false,"given":"Roc\u00edo","family":"Rodriguez","sequence":"additional","affiliation":[{"name":"Department of Construction and Agronomy, Universidad de Salamanca, 05003 \u00c1vila, Spain"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-3864-1201","authenticated-orcid":false,"given":"M\u00e1rcia","family":"Ara\u00fajo","sequence":"additional","affiliation":[{"name":"Campus Curitiba, Universidade Tecnol\u00f3gica Federal do Paran\u00e1, R. Dep. Heitor Alencar Furtado, 5000-Cidade Industrial de Curitiba, Curitiba 81280-340, PR, Brazil"}]},{"given":"Jo\u00e3o","family":"Rocha","sequence":"additional","affiliation":[{"name":"Mechanical Engineering Department, Instituto Polit\u00e9cnico de Bragan\u00e7a, Campus de Santa Apol\u00f3nia, 5300-253 Bragan\u00e7a, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-6345-4825","authenticated-orcid":false,"given":"Roberto","family":"Garc\u00eda-Mart\u00edn","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, University of Salamanca, Campus Viriato, Avenida Requejo, 49022 Zamora, Spain"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-6300-148X","authenticated-orcid":false,"given":"Jo\u00e3o","family":"Ribeiro","sequence":"additional","affiliation":[{"name":"Centro de Investiga\u00e7\u00e3o de Montanha (CIMO), Instituto Polit\u00e9cnico de Bragan\u00e7a, Campus de Santa Apol\u00f3nia, 5300-253 Bragan\u00e7a, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-1384-2819","authenticated-orcid":false,"given":"Javier","family":"Pisonero","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, University of Salamanca, Campus Viriato, Avenida Requejo, 49022 Zamora, Spain"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-9285-7834","authenticated-orcid":false,"given":"Manuel","family":"Rodr\u00edguez-Mart\u00edn","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, University of Salamanca, Campus Viriato, Avenida Requejo, 49022 Zamora, Spain"}]}],"member":"1968","published-online":{"date-parts":[[2025,6,14]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","unstructured":"Gibson, I., Rosen, D., and Stucker, B. 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