Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method

Abstract

Fused deposition modeling (FDM) is one of the most affordable and widespread additive manufacturing (AM) technologies. Despite its simplistic implementation, the physics behind this FDM process is very complex and involves rapid heating and cooling of the polymer feedstock. As a result, highly non-uniform internal stresses develop within the part, which can cause warpage deformation. The severity of the warpage is highly dependent on the process parameters involved, and therefore, currently extensive experimental studies are ongoing to assess their influence on the final accuracy of the part. In this study, a thermomechanical Finite Element model of the 3D printing process was developed using ANSYS. This model was compared against experimental results and several other analytical models available in the literature. The developed Finite Element Analysis (FEA) model demonstrated a good qualitative and quantitative correlation with the experimental results. An L9 orthogonal array, from Taguchi Design of Experiments, was used for the optimization of the warpage based on experimental results and numerical simulations. The optimum process parameters were identified for each objective and parts were printed using these process parameters. Both parts showed an approximately equal warpage value of 320 μm, which was the lowest among all 10 runs of the L9 array. Additionally, this model is extended to predict the warpage of FDM printed multi-material parts. The relative percentage error between the numerical and experimental warpage results for alternating and sandwich specimens are found to be 1.4% and 9.5%, respectively.

Strategies To Modify the Surface and Bulk Properties of 3D-Printed Solid Scaffolds for Tissue Engineering Applications

“…Moreover, optimizing the consequential operating parameters can lead to developing materials with better compressive, tensile, and fracture strength. Temperature is an important determinant operating parameter that can lead to mechanical defects such as poor bonding, wrinkling, and warpage of the printed material . Nonuniform shrinkage in the internal parts and no effect on the sides in response to the rapid heating and cooling occur during the printing process, leading to the warping of the part.…”

“…Significant parameters, i.e., model layer’s thickness and bed temperature, were chosen for the application through ANSYS. Although the present model tends to overestimate the defect, the error percentage is relatively low . Another defect commonly observed in 3D-printed materials of PLA is low isotopic fracture strength because of the low adhesion strength between the adjacent layers, which leads to fracture on the application of load.…”

“…Recently, some researchers have expressed that raster scanning speed and pattern, degree of fusion between the molten filaments, and effect of the cooling pattern of the molten extruded filament play a vital role in determining the bulk and surface properties of the 3D-printed scaffolds. As a result, the components/devices designed and fabricated lack the requisite mechanical properties and surface texture . Moreover, conventionally, the ability to tailor mechanical properties is primarily restricted to operating parameters like infill density, which determines the material density in a fabricated component or device .…”

“…As a result, the components/devices designed and fabricated lack the requisite mechanical properties and surface texture. 15 Moreover, conventionally, the ability to tailor mechanical properties is primarily restricted to operating parameters like infill density, which determines the material density in a fabricated component or device. 16 Further, the base material used in FDM significantly determines the final mechanical/surface properties of 3D-printed components.…”

3D‐Printed Functional Polymers and Nanocomposites: Defects Characterization and Product Quality Improvement

“…The results indicate that additional polymer interdiffusion and better interlayer bonding occurred in the parts as a result of the higher ambient temperature. Syrlybayev et al [ 208 ] applied a transient thermomechanical finite‐element model to predict warpage during fabrication of an ABS material by FFF and optimize the process parameters. At the optimum process parameters of 0.3 mm layer thickness, 95 °C platform temperature, and 240 °C nozzle temperature, the measured warpage was 310 and 320 μm for the simulation and experiment, respectively.…”