Development and validation of extrusion deposition additive manufacturing process simulations

Brenken, Bastian; Barocio, Eduardo; Favaloro, Anthony J.; Kunc, Vlastimil; Pipes, R. Byron

doi:10.1016/j.addma.2018.10.041

Cited by 77 publications

(58 citation statements)

References 8 publications

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“…Extrusion-based additive manufacturing of thermoplastic polymers is a thermally driven process. Thermal history affects viscoelastic deformation [1][2][3], bonding [4][5][6][7][8], and residual stresses [9,10]. Consequently, dimensional accuracy and the strength of the manufactured part are driven by the thermal history of the part.…”

Section: Introductionmentioning

confidence: 99%

“…Zhou et al [45] described a voxelization-based finite element simulation to simulate the thermal history of 3D-printed parts. Brenken et al [3] used FEA modeling to simulate the thermal history, final deformed shape, and residual stresses in the 3D-printed short-carbon-fiber-reinforced ABS polymer. Finite difference methods and finite element methods solve systems of linear equations for each time step during the period of simulation.…”

Section: Introductionmentioning

confidence: 99%

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Discrete-Event Simulation Thermal Model for Extrusion-Based Additive Manufacturing of PLA and ABS

Bhandari

Lopez-Anido

2020

Materials

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The material properties of thermoplastic polymer parts manufactured by the extrusion-based additive manufacturing process are highly dependent on the thermal history. Different numerical models have been proposed to simulate the thermal history of a 3D-printed part. However, they are limited due to limited geometric applicability; low accuracy; or high computational demand. Can the time–temperature history of a 3D-printed part be simulated by a computationally less demanding, fast numerical model without losing accuracy? This paper describes the numerical implementation of a simplified discrete-event simulation model that offers accuracy comparable to a finite element model but is faster by two orders of magnitude. Two polymer systems with distinct thermal properties were selected to highlight differences in the simulation of the orthotropic response and the temperature-dependent material properties. The time–temperature histories from the numerical model were compared to the time–temperature histories from a conventional finite element model and were found to match closely. The proposed highly parallel numerical model was approximately 300–500 times faster in simulating thermal history compared to the conventional finite element model. The model would enable designers to compare the effects of several printing parameters for specific 3D-printed parts and select the most suitable parameters for the part.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Discrete-Event Simulation Thermal Model for Extrusion-Based Additive Manufacturing of PLA and ABS

Bhandari

Lopez-Anido

2020

Materials

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“…On the basis of the theoretical models obtained [22], Boschetto and Botini [24] proposed a method for working directly on solid CAD models, and for improving dimensional precision. Brenken et al [25] developed a simulation tool named Additive3D to model the FFF process for fiber-reinforced thermoplastic composites.…”

Section: Introductionmentioning

confidence: 99%

Analysis of PLA Geometric Properties Processed by FFF Additive Manufacturing: Effects of Process Parameters and Plate-Extruder Precision Motion

et al. 2019

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The evolution of fused filament fabrication (FFF) technology, initially restricted to the manufacturing of prototypes, has led to its application in the manufacture of finished functional products with excellent mechanical properties. However, FFF technology entails drawbacks in aspects, such as dimensional and geometric precision, and surface finish. These aspects are crucial for the assembly and service life of functional parts, with geometric qualities lagging far behind the optimum levels obtained by conventional manufacturing processes. A further shortcoming is the proliferation of low cost FFF 3D printers with low quality mechanical components, and malfunctions that have a critical impact on the quality of finished products. FFF product quality is directly influenced by printer settings, material properties in terms of cured layers, and the functional mechanical efficiency of the 3D printer. This paper analyzes the effect of the build orientation (Bo), layer thickness (Lt), feed rate (Fr) parameters, and plate-extruder movements on the dimensional accuracy, flatness error, and surface texture of polylactic acid (PLA) using a low cost open-source FFF 3D printer. The mathematical modelling of geometric properties was performed using artificial neural networks (ANN). The results showed that thinner layer thickness generated lower dimensional deviations, and feed rate had a minor influence on dimensional accuracy. The flatness error and surface texture showed a quasi-linear behavior correlated to layer thickness and feed rate, with alterations produced by 3D printer malfunctions. The mathematical models provide a comprehensive analysis of the geometric behavior of PLA processing by FFF, in order to identify optimum print settings for the processing of functional components.

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“…Semi‐crystalline materials are of particular interest as this class of polymers generally outperforms amorphous polymers in applications where strength, use temperature range, and barrier properties are important . However, crystallinity also makes their manufacture by FFF challenging due to the shrinking and warping that occurs during crystallization, which induces out of plane deformation during printing . Much of the work in FFF of semi‐crystalline polymers focuses on high‐performance thermoplastics including poly(ether ether ketone) (PEEK) and poly(phenylene sulfide) (PPS) .…”

Section: Background and Motivationmentioning

confidence: 99%

“…However, crystallinity also makes their manufacture by FFF challenging due to the shrinking and warping that occurs during crystallization, which induces out of plane deformation during printing . Much of the work in FFF of semi‐crystalline polymers focuses on high‐performance thermoplastics including poly(ether ether ketone) (PEEK) and poly(phenylene sulfide) (PPS) . Other researchers have reported screening rheological properties for poly(ether ketone ketone) (PEKK), a crystallizable polymer, but do not include discussions on crystallization or warping of printed parts …”

Section: Background and Motivationmentioning

confidence: 99%

Semi‐Crystalline Polymer Blends for Material Extrusion Additive Manufacturing Printability: A Case Study with Poly(ethylene terephthalate) and Polypropylene

Chatham

Zawaski

Bobbitt³

et al. 2019

Macro Materials & Eng

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Semi‐crystalline polymers are an important class of materials for engineering applications due to their high modulus and barrier properties. Traditional manufacturing methods process semi‐crystalline polymers via rigid molds and well‐controlled temperature and pressure environments to handle the significant change in specific volume occurring during crystallization; however, material extrusion additive manufacturing does not use these features. This often leads to warpage‐induced build failure in fused filament fabrication (FFF). To enable FFF of semi‐crystalline polymers, this work investigates characteristics of immiscible polymer blends (e.g., disparate crystallization behavior and phase separation) to mitigate warping failure during printing. A series of poly(ethylene terephthalate)/polypropylene/polypropylene–graft–maleic anhydride blends are explored and the effect of thermal and morphological characteristics on printability is analyzed. It is shown that these blends can be extruded into filament and printed into a 3D structure. Extrapolations indicate that phase‐separated blends with increased total crystallization half‐time are beneficial for FFF printing.

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Development and validation of extrusion deposition additive manufacturing process simulations

Cited by 77 publications

References 8 publications

Discrete-Event Simulation Thermal Model for Extrusion-Based Additive Manufacturing of PLA and ABS

Discrete-Event Simulation Thermal Model for Extrusion-Based Additive Manufacturing of PLA and ABS

Analysis of PLA Geometric Properties Processed by FFF Additive Manufacturing: Effects of Process Parameters and Plate-Extruder Precision Motion

Semi‐Crystalline Polymer Blends for Material Extrusion Additive Manufacturing Printability: A Case Study with Poly(ethylene terephthalate) and Polypropylene

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