29 May 2024

Mesoscale Multiphysics Simulations of the Fused Deposition Additive Manufacturing Process

Abstract: As part of an ongoing effort to better understand the multiscale effects of fused deposition additive manufacturing, this work centers on a multiphysics, mesoscale approach for the simulation of the extrusion and solidification processes associated with fused deposition modeling. Restricting the work to a single line scan, we focus on the application of polylactic acid. In addition to heat, momentum, and mass transfer, the solid-liquid–vapor interface is simulated using a front-tracking, level-set method. The results focus on the evolving temperature, viscosity, and volume fraction and are cast within a set of parametric studies to include the nozzle and extrusion velocities as well as the extrusion temperature. Among other findings, it was observed that fused deposition modeling can be effectively modeled using a front-tracking method (i.e., the level-set method) in concert with a moving mesh and temperature-dependent porosity function.