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Simulated filament shapes in embedded 3D printing.

Leanne M Friedrich1, Jonathan E Seppala1

  • 1Materials Science and Engineering Division, National Institute of Standards and Technology, Gaithersburg, MD 20899, USA. jonathan.seppala@nist.gov.

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|July 23, 2021
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Summary

This study reveals how ink rheology, support fluid properties, and surface tension affect embedded 3D printing quality. Yield stress fluids in supports create more stable filaments, crucial for precise 3D printing applications.

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Area of Science:

  • Materials Science
  • Fluid Dynamics
  • Additive Manufacturing

Background:

  • Embedded 3D printing allows complex structure fabrication using fluid inks in support baths.
  • Techniques include embedded ink writing (EIW) and embedded droplet printing (EDP).
  • Materials can be Newtonian or yield stress fluids, exhibiting elastic and shear-thinning behaviors.

Purpose of the Study:

  • To investigate the influence of ink rheology, support rheology, and surface tension on filament morphology in embedded 3D printing.
  • To guide material selection and identify scaling relationships for improved print quality.
  • To understand the fundamental physics governing filament formation in yield stress fluids.

Main Methods:

  • Numerical simulations using OpenFOAM.
  • Analysis of single filament morphology under varying ink and support fluid properties.
  • Investigation of surface tension effects on print fidelity.

Main Results:

  • At low viscosities, surface tension dominates filament morphology.
  • When capillarity is reduced, ink/support viscosity ratio and support yield surface shape are critical.
  • Herschel-Bulkley (yield stress) supports yield more stable and accurately positioned filaments than Newtonian supports.
  • Non-zero surface tension aids in defect suppression for EIW and droplet formation for EDP.

Conclusions:

  • Material rheology and surface tension are key determinants of print quality in embedded 3D printing.
  • Yield stress fluids offer superior performance as support baths compared to Newtonian fluids.
  • Understanding these parameters is essential for optimizing complex 3D structure manufacturing.