Melt flow behaviour of poly-epsilon-caprolactone in fused deposition modelling

Fused deposition modelling (FDM) is an extrusion based Rapid prototyping (RP) technique which can be used to fabricate tissue engineering scaffolds. The present work focuses on the study of the melt flow behaviour (MFB) of Poly-epsilon-caprolactone (PCL) as a representative biomaterial, on the FDM. The MFB significantly affects the quality of the scaffold which depends not only on the pressure gradient, its velocity, and the temperature gradients but also physical properties like the melt temperature and rheology. The MFB is studied using two methods: mathematical modelling and finite element analysis (FEA) using Ansys(R). The MFB is studied using accurate channel geometry by varying filament velocity at the entry and by varying nozzle diameters and angles at the exit. The comparative results of both mathematical modelling and FEA suggest that the pressure drop and the velocities of the melt flow depend on the flow channel parameters. One inference of particular interest is the temperature gradient of the PCL melt, which shows that it liquefies within 35% of the channel length. These results are invaluable to better understand the MFB of biomaterials that affects the quality of the scaffold built via FDM and can also be used to predict the MFB of other biomaterials.