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Computational Fluid Dynamics Modeling of Top-Down Digital Light Processing Additive Manufacturing.

Hesam Moghadasi1,2, Md Tusher Mollah2, Deepak Marla3

  • 1School of Mechanical Engineering, Iran University of Science and Technology (IUST), Narmak, Tehran 16846-13114, Iran.

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Summary

Computational fluid dynamics (CFD) simulations optimize Digital Light Processing (DLP) 3D printing. Key parameters like viscosity and speed impact print stability, guiding optimal process choices for accuracy.

Keywords:
additive manufacturing (AM)computational fluid dynamics (CFD)digital light processing (DLP)stability timevat photopolymerization

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Area of Science:

  • Additive Manufacturing
  • Fluid Dynamics
  • Polymer Science

Background:

  • Digital Light Processing (DLP) is a popular 3D printing method using photocurable resins.
  • Part accuracy in DLP is contingent on process parameters and resin properties.
  • Understanding fluid behavior is crucial for optimizing DLP printing.

Purpose of the Study:

  • To investigate the influence of process parameters on fluid interface stability in top-down DLP 3D printing.
  • To develop a computational fluid dynamics (CFD) model for simulating DLP printing.
  • To identify optimal parameters for enhanced print accuracy and stability.

Main Methods:

  • Utilized computational fluid dynamics (CFD) simulations for top-down DLP 3D printing.
  • Analyzed the effects of viscosity, traveling speed, traveling speed ratio (TSR), layer thickness, and travel distance.
  • Evaluated 13 different simulation cases to determine fluid interface stability time.

Main Results:

  • Higher fluid viscosity increases stability time.
  • Increased traveling speed ratio (TSR) decreases stability time, though less significantly than viscosity.
  • Increasing printed layer thickness and travel distance reduces stability time.

Conclusions:

  • Optimal process parameter selection is essential for practical and accurate DLP 3D printing.
  • The developed numerical model aids in optimizing DLP process parameters.
  • CFD simulations provide valuable insights into the complex fluid dynamics of DLP printing.