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Rotating bending fatigue performance of FFF-fabricated PLA HD and ABS polymers: experimental characterization, numerical modeling and critical infill influence configuration.

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Title: Rotating bending fatigue performance of FFF-fabricated PLA HD and ABS polymers: experimental characterization, numerical modeling and critical infill influence configuration.
Authors: Zahir, Zineb1 (AUTHOR) zahir.zineb12@gmail.com, Hanafi, Issam2 (AUTHOR) hanafi.issam@yahoo.fr, El Bahaoui, Jalal1 (AUTHOR) jelbahaoui@uae.ac.ma, Mata Cabrera, Francisco3 (AUTHOR), Barea del Cerro, Rafael4 (AUTHOR) rbarea@nebrija.es, Gomez Lendinez, Daniel4 (AUTHOR) dgomezle@nebrija.es, Calderón Herrera, David3 (AUTHOR)
Source: Rapid Prototyping Journal. 2026, Vol. 32 Issue 4, p978-993. 16p.
Subjects: Fused deposition modeling, Material fatigue, Acrylonitrile butadiene styrene resins, Polylactic acid, Testing laboratories, Computer simulation
Abstract: Purpose: This study aims to quantify the rotating-bending fatigue performance of fused filament fabrication (FFF) polylactic acid (high density) (PLA HD) and ABS and validate a predictive framework to support design and life assessment of fatigue-critical AM components. Design/methodology/approach: The authors combined quasi-static testing (American society for testing and materials D638/D695), rotating-bending fatigue (15–45 MPa, 10–20 Hz) and FE modeling (ABAQUS + fe-safe with ductile damage). Specimens used two architectures: 20% grid infill (A) and 100% infill (B). Surface roughness and frequency sensitivity were assessed. Findings: Configuration B improved tensile performance (PLA HD: 57.7 MPa strength, 2.98 GPa modulus; ABS: 25.0 MPa strength) and extended fatigue life by 2.5–4.2×. Endurance limits were 20 MPa (PLA HD) and 15 MPa (ABS). Surface finishing to Ra < 10µm increased fatigue life by 25%–40%. The model achieved R > 0.95 for tensile response and factor-of-two compliance of 92% (PLA HD) and 88% (ABS) for fatigue prediction. Originality/value: The authors provide rotating-bending S–N curves with statistical bounds for FFF PLA HD/ABS, quantify architecture and surface-finish effects, and deliver a validated, orientation-aware predictive workflow. These results translate into design allowables and process controls for safer deployment of AM polymers in bending-dominated, high-cycle applications. [ABSTRACT FROM AUTHOR]
Copyright of Rapid Prototyping Journal is the property of Emerald Publishing Limited and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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DbLabel: Engineering Source
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  Data: Rotating bending fatigue performance of FFF-fabricated PLA HD and ABS polymers: experimental characterization, numerical modeling and critical infill influence configuration.
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  Data: &lt;searchLink fieldCode=&quot;AR&quot; term=&quot;%22Zahir%2C+Zineb%22&quot;&gt;Zahir, Zineb&lt;/searchLink&gt;&lt;relatesTo&gt;1&lt;/relatesTo&gt; (AUTHOR)&lt;i&gt; zahir.zineb12@gmail.com&lt;/i&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;AR&quot; term=&quot;%22Hanafi%2C+Issam%22&quot;&gt;Hanafi, Issam&lt;/searchLink&gt;&lt;relatesTo&gt;2&lt;/relatesTo&gt; (AUTHOR)&lt;i&gt; hanafi.issam@yahoo.fr&lt;/i&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;AR&quot; term=&quot;%22El+Bahaoui%2C+Jalal%22&quot;&gt;El Bahaoui, Jalal&lt;/searchLink&gt;&lt;relatesTo&gt;1&lt;/relatesTo&gt; (AUTHOR)&lt;i&gt; jelbahaoui@uae.ac.ma&lt;/i&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;AR&quot; term=&quot;%22Mata+Cabrera%2C+Francisco%22&quot;&gt;Mata Cabrera, Francisco&lt;/searchLink&gt;&lt;relatesTo&gt;3&lt;/relatesTo&gt; (AUTHOR)&lt;br /&gt;&lt;searchLink fieldCode=&quot;AR&quot; term=&quot;%22Barea+del+Cerro%2C+Rafael%22&quot;&gt;Barea del Cerro, Rafael&lt;/searchLink&gt;&lt;relatesTo&gt;4&lt;/relatesTo&gt; (AUTHOR)&lt;i&gt; rbarea@nebrija.es&lt;/i&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;AR&quot; term=&quot;%22Gomez+Lendinez%2C+Daniel%22&quot;&gt;Gomez Lendinez, Daniel&lt;/searchLink&gt;&lt;relatesTo&gt;4&lt;/relatesTo&gt; (AUTHOR)&lt;i&gt; dgomezle@nebrija.es&lt;/i&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;AR&quot; term=&quot;%22Calder&#243;n+Herrera%2C+David%22&quot;&gt;Calder&#243;n Herrera, David&lt;/searchLink&gt;&lt;relatesTo&gt;3&lt;/relatesTo&gt; (AUTHOR)
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  Data: &lt;searchLink fieldCode=&quot;JN&quot; term=&quot;%22Rapid+Prototyping+Journal%22&quot;&gt;Rapid Prototyping Journal&lt;/searchLink&gt;. 2026, Vol. 32 Issue 4, p978-993. 16p.
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  Data: &lt;searchLink fieldCode=&quot;DE&quot; term=&quot;%22Fused+deposition+modeling%22&quot;&gt;Fused deposition modeling&lt;/searchLink&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;DE&quot; term=&quot;%22Material+fatigue%22&quot;&gt;Material fatigue&lt;/searchLink&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;DE&quot; term=&quot;%22Acrylonitrile+butadiene+styrene+resins%22&quot;&gt;Acrylonitrile butadiene styrene resins&lt;/searchLink&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;DE&quot; term=&quot;%22Polylactic+acid%22&quot;&gt;Polylactic acid&lt;/searchLink&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;DE&quot; term=&quot;%22Testing+laboratories%22&quot;&gt;Testing laboratories&lt;/searchLink&gt;&lt;br /&gt;&lt;searchLink fieldCode=&quot;DE&quot; term=&quot;%22Computer+simulation%22&quot;&gt;Computer simulation&lt;/searchLink&gt;
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Purpose: This study aims to quantify the rotating-bending fatigue performance of fused filament fabrication (FFF) polylactic acid (high density) (PLA HD) and ABS and validate a predictive framework to support design and life assessment of fatigue-critical AM components. Design/methodology/approach: The authors combined quasi-static testing (American society for testing and materials D638/D695), rotating-bending fatigue (15–45 MPa, 10–20 Hz) and FE modeling (ABAQUS + fe-safe with ductile damage). Specimens used two architectures: 20% grid infill (A) and 100% infill (B). Surface roughness and frequency sensitivity were assessed. Findings: Configuration B improved tensile performance (PLA HD: 57.7 MPa strength, 2.98 GPa modulus; ABS: 25.0 MPa strength) and extended fatigue life by 2.5–4.2&#215;. Endurance limits were 20 MPa (PLA HD) and 15 MPa (ABS). Surface finishing to Ra &lt; 10&#181;m increased fatigue life by 25%–40%. The model achieved R &gt; 0.95 for tensile response and factor-of-two compliance of 92% (PLA HD) and 88% (ABS) for fatigue prediction. Originality/value: The authors provide rotating-bending S–N curves with statistical bounds for FFF PLA HD/ABS, quantify architecture and surface-finish effects, and deliver a validated, orientation-aware predictive workflow. These results translate into design allowables and process controls for safer deployment of AM polymers in bending-dominated, high-cycle applications. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: &lt;i&gt;Copyright of Rapid Prototyping Journal is the property of Emerald Publishing Limited and its content may not be copied or emailed to multiple sites without the copyright holder&#39;s express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.&lt;/i&gt; (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
  BibEntity:
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 16
        StartPage: 978
    Subjects:
      – SubjectFull: Fused deposition modeling
        Type: general
      – SubjectFull: Material fatigue
        Type: general
      – SubjectFull: Acrylonitrile butadiene styrene resins
        Type: general
      – SubjectFull: Polylactic acid
        Type: general
      – SubjectFull: Testing laboratories
        Type: general
      – SubjectFull: Computer simulation
        Type: general
    Titles:
      – TitleFull: Rotating bending fatigue performance of FFF-fabricated PLA HD and ABS polymers: experimental characterization, numerical modeling and critical infill influence configuration.
        Type: main
  BibRelationships:
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      – PersonEntity:
          Name:
            NameFull: Zahir, Zineb
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            NameFull: Hanafi, Issam
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            NameFull: El Bahaoui, Jalal
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            NameFull: Mata Cabrera, Francisco
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            NameFull: Barea del Cerro, Rafael
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            NameFull: Gomez Lendinez, Daniel
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            NameFull: Calderón Herrera, David
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            – D: 01
              M: 04
              Text: 2026
              Type: published
              Y: 2026
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              Value: 32
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              Value: 4
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            – TitleFull: Rapid Prototyping Journal
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