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Related Experiment Video

Updated: Jun 8, 2025

Fused Filament Fabrication FFF of Metal-Ceramic Components
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Simulated inter-filament fusion in embedded 3D printing.

Leanne M Friedrich1, Ross T Gunther2

  • 1Material Measurement Laboratory, National Institute of Standards and Technology, 100 Bureau Drive, Gaithersburg, MD 20899, United States of America.

Biofabrication
|November 7, 2024
PubMed
Summary

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Filament Disturbance and Fusion during Embedded 3D Printing of Silicones.

ACS biomaterials science & engineering·2024
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Suppression of Filament Defects in Embedded 3D Printing.

ACS applied materials & interfaces·2022
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Simulated filament shapes in embedded 3D printing.

Soft matter·2021
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Embedded 3D printing (EMB3D) simulations reveal that controlling support fluid flow around the nozzle is key to improving dimensional accuracy and mechanical properties. Careful nozzle path planning and filament spacing are crucial for high-quality complex structures.

Area of Science:

  • Biotechnology
  • Materials Science
  • Fluid Dynamics

Background:

  • Embedded 3D printing (EMB3D) allows for complex structures like tissues and organs.
  • High-quality dimensional accuracy and mechanical properties in EMB3D are not well-documented.
  • Existing research lacks detailed understanding of EMB3D's underlying physics.

Purpose of the Study:

  • To investigate the physics of part deformation and filament fusion in EMB3D using computational fluid dynamics (CFD).
  • To identify strategies for improving dimensional accuracy and mechanical properties in EMB3D.
  • To disentangle complex fluid dynamics phenomena like yielding, viscous dissipation, and interfacial tension effects.

Main Methods:

  • Computational fluid dynamics (CFD) simulations using OpenFOAM.
Keywords:
3d printingOpenFOAMadditive manufacturingbioprintingcomputational fluid dynamicsrheology

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  • Analysis of support fluid flow dynamics around the printing nozzle.
  • Isolation and study of rheology and interfacial tension effects.

    • Main Results:

    • Part deformation and filament fusion are governed by support fluid flow around the nozzle.
    • Nozzle proximity to existing parts during non-printing moves significantly impacts deformation, especially with non-zero interfacial tension.
    • Optimal filament spacing is critical, requiring tighter spacing for vertical walls in non-Newtonian fluids to prevent support entrapment and ensure proper fusion.
    • Interfacial tension improves fusion but can also introduce shape defects.

    Conclusions:

    • CFD simulations provide critical insights into EMB3D's physics, difficult to obtain experimentally.
    • Strategies to control nozzle motion and filament spacing are essential for high-fidelity EMB3D.
    • Development of specialized slicing algorithms accounting for EMB3D-specific defects is needed to enhance construct quality.