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<p>In Fused Filament Fabrication (FFF), the Z-seam is the start–stop discontinuity formed at the beginning and end of each deposited perimeter, degrades both dimensional accuracy and crash energy absorption by acting as a stress concentration and tear-initiation site. This study quantitatively assesses advanced mitigation strategies to simultaneously optimize dimensional fidelity and crashworthiness in ABS circular tubes. Seam modification strategies comprising Pressure Advance to compensate for nozzle pressure lag and the Scarf Joint seam to replace abrupt steps with tapered overlaps were evaluated individually and in combination. Seam placement using Aligned, Back, and Nearest positions was controlled via a full factorial design of twelve build conditions. Quasi-static axial compression tests quantified energy absorption metrics, while full-field 3D scan-to-CAD analysis quantified dimensional deviation and oversize. Pressure Advance increased stiffness by stabilizing extrusion flow, whereas the Scarf Joint redistributed the seam discontinuity, reduced peak force, and promoted progressive folding. Seam placement strongly governed energy absorption where Back placement consistently outperformed other configurations. The combined Pressure Advance–Scarf Joint configuration with Back seam placement achieved the optimal multi-objective response, delivering a SEA of 16.95&#xa0;kJ kg⁻<sup>1</sup>, EA of 23.50&#xa0;daJ, and CFE of 50.96%, while also exhibiting the high dimensional compliance. To resolve trade-offs between geometric accuracy and mechanical performance, a hybrid framework integrating two-way ANOVA and SHapley Additive exPlanations (SHAP) was applied. SHAP attribution revealed that seam placement governed absorbed energy variance, whereas seam modification dominated stiffness and crush force efficiency, establishing Z-seam control as an optimization-ready design variable for crashworthy FFF components.</p>

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Effects of Z-seam mitigation on energy absorption and dimensional accuracy of printed circular tubes

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年8月4日

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  • E. Avcioglu,
  • M. Eltis

摘要

In Fused Filament Fabrication (FFF), the Z-seam is the start–stop discontinuity formed at the beginning and end of each deposited perimeter, degrades both dimensional accuracy and crash energy absorption by acting as a stress concentration and tear-initiation site. This study quantitatively assesses advanced mitigation strategies to simultaneously optimize dimensional fidelity and crashworthiness in ABS circular tubes. Seam modification strategies comprising Pressure Advance to compensate for nozzle pressure lag and the Scarf Joint seam to replace abrupt steps with tapered overlaps were evaluated individually and in combination. Seam placement using Aligned, Back, and Nearest positions was controlled via a full factorial design of twelve build conditions. Quasi-static axial compression tests quantified energy absorption metrics, while full-field 3D scan-to-CAD analysis quantified dimensional deviation and oversize. Pressure Advance increased stiffness by stabilizing extrusion flow, whereas the Scarf Joint redistributed the seam discontinuity, reduced peak force, and promoted progressive folding. Seam placement strongly governed energy absorption where Back placement consistently outperformed other configurations. The combined Pressure Advance–Scarf Joint configuration with Back seam placement achieved the optimal multi-objective response, delivering a SEA of 16.95 kJ kg⁻1, EA of 23.50 daJ, and CFE of 50.96%, while also exhibiting the high dimensional compliance. To resolve trade-offs between geometric accuracy and mechanical performance, a hybrid framework integrating two-way ANOVA and SHapley Additive exPlanations (SHAP) was applied. SHAP attribution revealed that seam placement governed absorbed energy variance, whereas seam modification dominated stiffness and crush force efficiency, establishing Z-seam control as an optimization-ready design variable for crashworthy FFF components.