Discrete-Event Simulation Thermal Model for Extrusion-Based Additive Manufacturing of PLA and ABS

Area of Science:

• Materials Science
• Computational Modeling
• Additive Manufacturing

Background:

• Thermoplastic polymer part properties in extrusion-based additive manufacturing are sensitive to thermal history.
• Existing numerical models for simulating thermal history face limitations in geometric applicability, accuracy, or computational demand.

Purpose of the Study:

• To develop and implement a computationally efficient numerical model for simulating the time-temperature history of 3D-printed parts.
• To achieve accuracy comparable to finite element models while significantly reducing computational cost.

Main Methods:

• Numerical implementation of a simplified discrete-event simulation model.
• Validation using two polymer systems with distinct thermal properties.
• Comparison of simulation results with a conventional finite element model.

Main Results:

• The discrete-event simulation model demonstrated accuracy comparable to finite element models.
• The proposed model achieved simulation speeds 300-500 times faster than conventional finite element models.
• Close matching of time-temperature histories between the proposed model and finite element analysis.

Conclusions:

• A fast and accurate numerical model for simulating the thermal history of 3D-printed parts has been developed.
• This model significantly reduces computational demand, enabling efficient design parameter exploration.
• The model facilitates the selection of optimal printing parameters for enhanced part performance.