Modelling of material deposition in big area additive manufacturing and 3D concrete printing

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Abstract

Big area additive manufacturing and 3D concrete printing are two technologies that upscale the material extrusion additive manufacturing concept to larger workpiece dimensions and higher build rates. This work presents a computation fluid dynamics model that simulates material extrusion and deposition using the software FLOW-3D. The numerical simulation is used to evaluate the cross-sectional shape of the printed beads. Several constitutive models have been considered to cover the wide range of material behaviours, including shear-thinning and visco-plasticity, that are expected in the flow of molten plastic and fresh concrete. The presence or absence of shear-thinning was found to have more influence on the cross-section of the bead than the actual values of the viscosity. The numerical results are also compared to the nominal bead’s dimensions used in slicer softwares. The conclusion of this study is that the actual bead’s dimensions can vary substantially from its nominal size, which is one of the phenomena that affects negatively the manufacturing precision.
Original languageEnglish
Title of host publicationProceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019)
EditorsA. Bernard, R.K. Leach, D.B. Pedersen, J.S. Taylor
PublisherThe European Society for Precision Engineering and Nanotechnology
Publication date2019
Pages151-154
ISBN (Electronic)978-0-9957751-5-2
Publication statusPublished - 2019
EventJoint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing - Ecole Centrale de Nantes, Nantes, France
Duration: 16 Sep 201918 Sep 2019

Conference

ConferenceJoint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing
LocationEcole Centrale de Nantes
CountryFrance
CityNantes
Period16/09/201918/09/2019

Keywords

  • Numerical simulation
  • Material extrusion
  • Big area additive manufacturing
  • 3D concrete printing
  • Constitutive model

Cite this

Comminal, R., Serdeczny, M. P., Ranjbar, N., Mehrali, M., Pedersen, D. B., Stang, H., & Spangenberg, J. (2019). Modelling of material deposition in big area additive manufacturing and 3D concrete printing. In A. Bernard, R. K. Leach, D. B. Pedersen, & J. S. Taylor (Eds.), Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019) (pp. 151-154). The European Society for Precision Engineering and Nanotechnology.
Comminal, Raphaël ; Serdeczny, Marcin Piotr ; Ranjbar, Navid ; Mehrali, Mehdi ; Pedersen, David Bue ; Stang, Henrik ; Spangenberg, Jon. / Modelling of material deposition in big area additive manufacturing and 3D concrete printing. Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). editor / A. Bernard ; R.K. Leach ; D.B. Pedersen ; J.S. Taylor. The European Society for Precision Engineering and Nanotechnology, 2019. pp. 151-154
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abstract = "Big area additive manufacturing and 3D concrete printing are two technologies that upscale the material extrusion additive manufacturing concept to larger workpiece dimensions and higher build rates. This work presents a computation fluid dynamics model that simulates material extrusion and deposition using the software FLOW-3D. The numerical simulation is used to evaluate the cross-sectional shape of the printed beads. Several constitutive models have been considered to cover the wide range of material behaviours, including shear-thinning and visco-plasticity, that are expected in the flow of molten plastic and fresh concrete. The presence or absence of shear-thinning was found to have more influence on the cross-section of the bead than the actual values of the viscosity. The numerical results are also compared to the nominal bead’s dimensions used in slicer softwares. The conclusion of this study is that the actual bead’s dimensions can vary substantially from its nominal size, which is one of the phenomena that affects negatively the manufacturing precision.",
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Comminal, R, Serdeczny, MP, Ranjbar, N, Mehrali, M, Pedersen, DB, Stang, H & Spangenberg, J 2019, Modelling of material deposition in big area additive manufacturing and 3D concrete printing. in A Bernard, RK Leach, DB Pedersen & JS Taylor (eds), Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). The European Society for Precision Engineering and Nanotechnology, pp. 151-154, Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing, Nantes, France, 16/09/2019.

Modelling of material deposition in big area additive manufacturing and 3D concrete printing. / Comminal, Raphaël; Serdeczny, Marcin Piotr; Ranjbar, Navid; Mehrali, Mehdi; Pedersen, David Bue; Stang, Henrik; Spangenberg, Jon.

Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). ed. / A. Bernard; R.K. Leach; D.B. Pedersen; J.S. Taylor. The European Society for Precision Engineering and Nanotechnology, 2019. p. 151-154.

Research output: Chapter in Book/Report/Conference proceedingConference abstract in proceedingsResearchpeer-review

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T1 - Modelling of material deposition in big area additive manufacturing and 3D concrete printing

AU - Comminal, Raphaël

AU - Serdeczny, Marcin Piotr

AU - Ranjbar, Navid

AU - Mehrali, Mehdi

AU - Pedersen, David Bue

AU - Stang, Henrik

AU - Spangenberg, Jon

PY - 2019

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N2 - Big area additive manufacturing and 3D concrete printing are two technologies that upscale the material extrusion additive manufacturing concept to larger workpiece dimensions and higher build rates. This work presents a computation fluid dynamics model that simulates material extrusion and deposition using the software FLOW-3D. The numerical simulation is used to evaluate the cross-sectional shape of the printed beads. Several constitutive models have been considered to cover the wide range of material behaviours, including shear-thinning and visco-plasticity, that are expected in the flow of molten plastic and fresh concrete. The presence or absence of shear-thinning was found to have more influence on the cross-section of the bead than the actual values of the viscosity. The numerical results are also compared to the nominal bead’s dimensions used in slicer softwares. The conclusion of this study is that the actual bead’s dimensions can vary substantially from its nominal size, which is one of the phenomena that affects negatively the manufacturing precision.

AB - Big area additive manufacturing and 3D concrete printing are two technologies that upscale the material extrusion additive manufacturing concept to larger workpiece dimensions and higher build rates. This work presents a computation fluid dynamics model that simulates material extrusion and deposition using the software FLOW-3D. The numerical simulation is used to evaluate the cross-sectional shape of the printed beads. Several constitutive models have been considered to cover the wide range of material behaviours, including shear-thinning and visco-plasticity, that are expected in the flow of molten plastic and fresh concrete. The presence or absence of shear-thinning was found to have more influence on the cross-section of the bead than the actual values of the viscosity. The numerical results are also compared to the nominal bead’s dimensions used in slicer softwares. The conclusion of this study is that the actual bead’s dimensions can vary substantially from its nominal size, which is one of the phenomena that affects negatively the manufacturing precision.

KW - Numerical simulation

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KW - 3D concrete printing

KW - Constitutive model

M3 - Conference abstract in proceedings

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BT - Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019)

A2 - Bernard, A.

A2 - Leach, R.K.

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A2 - Taylor, J.S.

PB - The European Society for Precision Engineering and Nanotechnology

ER -

Comminal R, Serdeczny MP, Ranjbar N, Mehrali M, Pedersen DB, Stang H et al. Modelling of material deposition in big area additive manufacturing and 3D concrete printing. In Bernard A, Leach RK, Pedersen DB, Taylor JS, editors, Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). The European Society for Precision Engineering and Nanotechnology. 2019. p. 151-154