Tribological Performance and Wear Mechanisms of Fused Deposition Modeling Polymers: An Integrative Theoretical and Experimental Synthesis

Abstract

Background: Additive manufacturing by fused deposition modelling (FDM) has transformed how thermoplastic parts are designed and produced, enabling rapid prototyping and bespoke functional components. However, the tribological performance—friction, wear, and abrasion resistance—of FDM-produced polymers remains a critical limitation for load-bearing and sliding applications (Cano-Vicent et al., 2021; Roy & Mukhopadhyay, 2020).

Objective: This article synthesizes the state of knowledge from materials science, tribology, rheology, and additive-manufacturing process engineering to produce a coherent, publication-ready examination of tribological behaviors of common FDM polymers (ABS, PLA, composites with fillers and lubricants), identify persistent research gaps, and propose rigorous methodologies for future investigation (Prabhu & Devaraju, 2020; Equbal et al., 2010).

Methods: The work integrates comparative literature analysis, theoretical elaboration on mechanisms (molecular mobility, glass transition, interfacial adhesion, asperity interactions), and a conceptual experimental framework including standardized sliding wear testers, parametric process mapping, and multiscale characterizations from nano- to macro-length scales (Dealy, 1992; Chartoff et al., 1994). Where empirical trends are reported from prior studies, results are described qualitatively and placed in mechanistic context (Srinivasan et al., 2020; Keshavamurthy et al., 2021).

Results: The synthesis reveals consistent patterns: anisotropic build-induced heterogeneity dominates mechanical and tribological response; filler type and dispersion govern load transfer and third-body formation; lubrication (both intrinsic via solid lubricants and extrinsic coatings) alters dominant wear regimes from adhesive to abrasive or fatigue-driven mechanisms; and rheological behavior during deposition determines interlayer bonding and thus surface and subsurface resistance to material removal (Roy & Mukhopadhyay, 2020; Mourya et al., 2023; Keshavamurthy et al., 2021).

Conclusions: Advancing tribological performance for FDM parts requires combined strategies: tailored polymer chemistry and nanofillers for viscoelastic tuning, deposition process control to minimize structural anisotropy, and engineered surface texturing or lubricant incorporation to manage contact mechanics. Robust methodology—multi-length-scale testing, statistical design of experiments, and mechanistic interpretation grounded in polymer physics—will be necessary to close critical research gaps identified herein (Aditya & Srinivas, 2023; Raichur et al., 2024).