<p>Additive manufacturing requires simulation tools that account for the influence of process history on the mechanical response of printed parts. This study evaluates a manufacturing-aware process-to-structure simulation workflow for fused filament fabrication (FFF) ABS-M30 specimens under three-point bending. The workflow couples AM process simulation with nonlinear structural finite element analysis by transferring process-induced information, including residual stresses, local material orientation, and as-manufactured geometry, from the process model to the structural model. A case study was performed on ABS-M30 specimens manufactured using a Stratasys F170 printer and tested according to ASTM D790. The manufacturing-aware model was compared with a conventional nominal CAD-based model and with experimental bending results. Over the 1–10% strain interval, the average stress deviation decreased from 7.67% for the nominal model to 5.27% for the manufacturing-aware model, corresponding to an average relative error reduction of approximately 31%. However, the improvement was strain-dependent and mainly limited to the elastic region. In the plastic regime, both numerical models continued to overestimate the experimental response, indicating that residual-stress mapping alone is insufficient to reproduce damage, interlayer debonding, void evolution, and fracture of FFF ABS-M30 specimens. The study therefore provides a critical assessment of the benefits and limitations of process-to-structure mapping for FFF parts, showing that manufacturing-aware simulations can partially improve elastic-region predictions but require calibrated anisotropic elastoplastic-damage models to predict the complete flexural response.</p>