Simulation of temperature profile in fused filament fabrication 3D printing method

Abstract

Purpose Temperature is a critical factor in the fused filament fabrication (FFF) process, which affects the flow behavior and adhesion of the melted filament and the mechanical properties of the final object. Therefore, modeling and predicting temperature in FFF is crucial for achieving high-quality prints, repeatability, process control and failure prediction. This study aims to investigate the melt deposition and temperature profile in FFF both numerically and experimentally using different Acrylonitrile Butadiene Styrene single-strand specimens. The process parameters, including layer thickness, nozzle temperature and build platform temperature, were varied. Design/methodology/approach COMSOL Multiphysics software was used to perform numerical simulations of fluid flow and heat transfer for the printed strands. The polymer melt/air interface was tracked using the coupling of continuity equation, equation of motion and the level set equation, and the heat transfer equation was used to simulate the temperature distribution in the deposited strand. Findings The numerical results show that increasing the nozzle temperature or layer thickness leads to an increase in temperature at points close to the nozzle, but the bed temperature is the main determinant of the overall layer temperature in low-thickness strands. The experimental temperature profile of the deposited strand was measured using an infrared (IR) thermal imager to validate the numerical results. The comparison between simulation and observed temperature at different points showed that the numerical model accurately predicts heat transfer in the three-dimensional (3D) printing of a single-strand under different conditions. Finally, a parametric analysis was performed to investigate the effect of selected parameters on the thermal history of the printed strand. Originality/value The numerical results show that increasing the nozzle temperature or layer thickness leads to an increase in temperature at points close to the nozzle, but the bed temperature is the main determinant of the overall layer temperature in low-thickness strands. The experimental temperature profile of the deposited strand was measured using an IR thermal imager to validate the numerical results. The comparison between simulation and observed temperature at different points showed that the numerical model accurately predicts heat transfer in the 3D printing of a single-strand under different conditions. Finally, a parametric analysis was performed to investigate the effect of selected parameters on the thermal history of the printed strand.

Additive manufactured parts surface treatment through impinged hot air jet technique the theoretical and experimental evaluation

“…The current issue and full text archive of this journal is available on Emerald Insight at: https://www.emerald.com/insight/1355-2546.htm developed as secondary processes to ameliorate the surface integrity and dimensional accuracy of the printed parts (Hashmi et al, 2023a;Tiwary et al, 2022a). The preprocessing techniques are divided into the optimization of printing machine structure (Chu et al, 2021;Marion et al, 2023;Xu et al, 2022) and feedstock filament (Dontsov et al, 2020;Ginoux et al, 2023;Yan et al, 2023), printing strategy optimization (Afsharkohan et al, 2023;Côt e et al, 2023;Jiang et al, 2022;Wang et al, 2021) including printing path, printing speed, build orientation and layer thicknessand slicing optimization methods (Mosleh et al, 2023;Nayyeri et al, 2022;Vinoth Babu et al, 2021).…”

“…, 2022; Wang et al. , 2021) – including printing path, printing speed, build orientation and layer thickness – and slicing optimization methods (Mosleh et al. , 2023; Nayyeri et al.…”

Numerical Modeling and Analysis of Transient and Three-Dimensional Heat Transfer in 3D Printing via Fused-Deposition Modeling (FDM)

“…Mosleh et al performed research on the thermal dynamics occurring during the initial layer deposition in 3D printing, specifically focusing on the numerical and experimental investigation of ABS deposition [18]. The examination employs both infrared thermometry and COMSOL Multiphysics software.…”