Path-Based Discrete Modeling and Process Simulation for Thermoplastic Fused Deposition Modeling Technology

Area of Science:

• Additive Manufacturing
• Materials Science
• Computational Mechanics

Background:

• Fused Deposition Modeling (FDM) is a widely used, cost-effective additive manufacturing (AM) technology.
• FDM parts often suffer from warping deformation due to thermal stresses during the printing process.
• Predicting this deformation is challenging due to complex material deposition paths.

Purpose of the Study:

• To develop a novel path-based discrete modeling and process simulation method for FDM.
• To improve the prediction of dimensional accuracy and warping in FDM-printed parts.
• To provide a simulation tool applicable to complex geometries and other AM processes.

Main Methods:

• A discrete modeling approach was used to reconstruct finite element (FE) models based on process parameters and toolpaths.
• The birth-death element method (BDEM) was employed within ANSYS 2022 R1 to simulate the thermo-mechanical coupling field.
• Custom computing programs were developed in C++ for the simulation.

Main Results:

• The developed simulation method accurately predicted warping deformations in FDM parts.
• Numerical examples using ABS material demonstrated strong agreement between simulated and real part deformations.
• The method proved effective for complex geometries.

Conclusions:

• The path-based discrete modeling and simulation method offers a reliable tool for predicting FDM part deformation.
• This approach can enhance dimensional accuracy and reduce warping in 3D printed components.
• The findings are transferable to other AM processes and complex part designs.