Abstract: To achieve precise and efficient progressive failure prediction for fused filament fabrication (FFF) 3D printing composite materials, this study investigates the tensile failure behavior of FFF 3D printing carbon fiber reinforced polymer (CFRP) perforated laminates, and the mechanistic exploration is conducted. A novel progressive failure analysis method is proposed, specifically developed for FFF 3D printing CFRP structures, which accurately simulates the coupled behavior of intra-layer failure and inter-layer delamination under hole-edge stress concentration while modifying the strength of printed materials considering in-situ effects. Systematic experimental investigations are conducted on 3D printing perforated laminates with diverse stacking configurations (cross-stacking, angle-stacking, mixed-stacking, and rotational-stacking), enabling multi-scale analysis from mesoscopic damage initiation to macroscopic structural failure to validate the proposed method and reveal the failure mechanisms. Results indicate that tensile failure of FFF 3D printing CFRP perforated laminates is dominated by fiber breakage and matrix cracking, accompanied by interlaminar Mode-II shear failure at stress concentration regions. Notably, in-situ effects induced by varying printing angles and clustered layer thicknesses in angle-stacking configurations resulted in up to 15.29% difference in ultimate bearing capacity among specimens with identical stacking orientations. The proposed model, incorporating empirical formula corrections for in-situ effects, demonstrates a mean prediction error of 4.51%. Thus, the progressive failure modeling framework establishes a theoretical foundation for bridge engineering applications of FFF 3D printing CFRP in critical load-bearing structures.