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Multiphysics Modeling and Experimental Investigation of the Deposition Process in Fused Filament Fabrication Method, under High-Viscosity and Non-Newtonian Material Flow

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Abstract

In this study, the process of thermoplastic material deposition during 3D printing has been investigated via a multiphysics approach, using numerical and experimental tools. Namely, through computational fluid dynamics modeling, details of the flow structure and heat transfer process of the deposited material from the nozzle head onto the bed have been investigated. Experimental trials were conducted to validate the results of the computational model, and a good conformity between the results was obtained, with error less than 8%. Both curling and fluid mechanical swing machine print patterns were captured, especially given the high-viscosity and non-Newtonian characteristics of the flow. In particular, in the conducted case on ABS, results indicated that the ratio of the extrudate diameter to the nozzle diameter is around 12%. At feed rates lower than 100 mm/min, the curling takes place, where the extruded material bends up against the direction of the injection at the nozzle. It was observed that the fluid mechanical swing machine pattern takes place at the feed rate-to-moving bed speed ratios higher than 1.0, and depending on the nozzle to bed gap. High fidelity numerical platforms are deemed critical to better comprehend and predict complex local phenomena taking place during fused filament fabrication, and accordingly to more reliably optimize the process parameters.

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Acknowledgment

The first author would like to thank Mr. Randy Venberg, President of Global Heat Transfer Ltd., and Dr. Hamidreza Zarei Rajani, R&D Manager at Global Heat Transfer Ltd., for their support and positive discussions toward fundamentals of the studied phenomena in complex heat and material transfer systems. The authors would also like to highly acknowledge Mr. Bryn Crawford and Mr. Kurt Yesilcimen from UBC for their valuable assistance during the experiments.

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Authors and Affiliations

  1. Composites Research Network-Okanagan Laboratory, School of Engineering, University of British Columbia, Kelowna, BC, Canada

    Mehdi Jahandardoost & Abbas S. Milani

  2. Materials and Manufacturing Research Institute, University of British Columbia, Kelowna, BC, Canada

    Mehdi Jahandardoost & Abbas S. Milani

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  1. Mehdi Jahandardoost
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  2. Abbas S. Milani
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Correspondence to Abbas S. Milani.

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This invited article is part of a special topical focus in the Journal of Materials Engineering and Performance on Additive Manufacturing. The issue was organized by Dr. William Frazier, Pilgrim Consulting, LLC; Mr. Rick Russell, NASA; Dr. Yan Lu, NIST; Dr. Brandon D. Ribic, America Makes; and Caroline Vail, NSWC Carderock.

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Jahandardoost, M., Milani, A.S. Multiphysics Modeling and Experimental Investigation of the Deposition Process in Fused Filament Fabrication Method, under High-Viscosity and Non-Newtonian Material Flow. J. of Materi Eng and Perform 30, 6913–6923 (2021). https://doi.org/10.1007/s11665-021-06061-z

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  • DOI: https://doi.org/10.1007/s11665-021-06061-z

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