Numerical simulations of the mesostructure formation in material extrusion additive manufacturing

Research output: Contribution to journalJournal articleResearchpeer-review

Abstract

A computational fluid dynamics model is used to predict the mesostructure formed by the successive deposition of parallel strands in material extrusion additive manufacturing. The numerical model simulates the extrusion of the material onto the substrate. The model takes into account the effect of the presence of the previously extruded material on the shape of the subsequently deposited strands. The simulated mesostructures are compared to optical micrographs of the mesostructures of 3D-printed samples, and the predictions agree well with the experiments. In addition, the influence of the layer thickness, the strand-to-strand distance, and the deposition configuration (with aligned or skewed layers) on the formation of the mesostructure is investigated. The simulations provide detailed information about the porosity, the inter- and intra-layer bond line densities, and the surface roughness of the mesostructures, which potentially can be used in a model-based slicing software.
Original languageEnglish
JournalAdditive Manufacturing
Volume28
Pages (from-to)419-429
ISSN2214-8604
DOIs
Publication statusPublished - 2019

Keywords

  • Material extrusion additive manufacturing
  • Fused deposition modeling
  • Numerical simulations
  • Mesostructure
  • Porosity

Cite this

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title = "Numerical simulations of the mesostructure formation in material extrusion additive manufacturing",
abstract = "A computational fluid dynamics model is used to predict the mesostructure formed by the successive deposition of parallel strands in material extrusion additive manufacturing. The numerical model simulates the extrusion of the material onto the substrate. The model takes into account the effect of the presence of the previously extruded material on the shape of the subsequently deposited strands. The simulated mesostructures are compared to optical micrographs of the mesostructures of 3D-printed samples, and the predictions agree well with the experiments. In addition, the influence of the layer thickness, the strand-to-strand distance, and the deposition configuration (with aligned or skewed layers) on the formation of the mesostructure is investigated. The simulations provide detailed information about the porosity, the inter- and intra-layer bond line densities, and the surface roughness of the mesostructures, which potentially can be used in a model-based slicing software.",
keywords = "Material extrusion additive manufacturing, Fused deposition modeling, Numerical simulations, Mesostructure, Porosity",
author = "Serdeczny, {Marcin P.} and Rapha{\"e}l Comminal and Pedersen, {David B.} and Jon Spangenberg",
year = "2019",
doi = "10.1016/j.addma.2019.05.024",
language = "English",
volume = "28",
pages = "419--429",
journal = "Additive Manufacturing",
issn = "2214-8604",
publisher = "Elsevier",

}

TY - JOUR

T1 - Numerical simulations of the mesostructure formation in material extrusion additive manufacturing

AU - Serdeczny, Marcin P.

AU - Comminal, Raphaël

AU - Pedersen, David B.

AU - Spangenberg, Jon

PY - 2019

Y1 - 2019

N2 - A computational fluid dynamics model is used to predict the mesostructure formed by the successive deposition of parallel strands in material extrusion additive manufacturing. The numerical model simulates the extrusion of the material onto the substrate. The model takes into account the effect of the presence of the previously extruded material on the shape of the subsequently deposited strands. The simulated mesostructures are compared to optical micrographs of the mesostructures of 3D-printed samples, and the predictions agree well with the experiments. In addition, the influence of the layer thickness, the strand-to-strand distance, and the deposition configuration (with aligned or skewed layers) on the formation of the mesostructure is investigated. The simulations provide detailed information about the porosity, the inter- and intra-layer bond line densities, and the surface roughness of the mesostructures, which potentially can be used in a model-based slicing software.

AB - A computational fluid dynamics model is used to predict the mesostructure formed by the successive deposition of parallel strands in material extrusion additive manufacturing. The numerical model simulates the extrusion of the material onto the substrate. The model takes into account the effect of the presence of the previously extruded material on the shape of the subsequently deposited strands. The simulated mesostructures are compared to optical micrographs of the mesostructures of 3D-printed samples, and the predictions agree well with the experiments. In addition, the influence of the layer thickness, the strand-to-strand distance, and the deposition configuration (with aligned or skewed layers) on the formation of the mesostructure is investigated. The simulations provide detailed information about the porosity, the inter- and intra-layer bond line densities, and the surface roughness of the mesostructures, which potentially can be used in a model-based slicing software.

KW - Material extrusion additive manufacturing

KW - Fused deposition modeling

KW - Numerical simulations

KW - Mesostructure

KW - Porosity

U2 - 10.1016/j.addma.2019.05.024

DO - 10.1016/j.addma.2019.05.024

M3 - Journal article

VL - 28

SP - 419

EP - 429

JO - Additive Manufacturing

JF - Additive Manufacturing

SN - 2214-8604

ER -