(603b) Computational Fluid Dynamics Simulation of the Fused Deposition Modeling Process: Effect of Temperature-Dependent Viscosity on the Shape of Extruded Strand

Fused Deposition Modeling (FDM) is a 3D printing technique based on extrusion of polymer melt. In the FDM process, polymer filaments are melted in the liquefier and then extruded layer by layer to build final products. Although the process is fast and cost-effective, the final product may have rough surface due to the deformation of the extruded strain. In this study, the effects of various process parameters on the morphology of the extruded strand have been investigated. Non-isothermal free surface flow simulation of the extrusion process was performed utilizing OpenFOAM, an open source simulation software, along with our development of a user-defined module. Simulation results for the dimensions (including thickness and width of layer) of an extruded strand have been validated by experimental results. The temperature effect on the surface roughness based on these will be also discussed.