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

Fused deposition modeling (FDM), as one of the most widespread and cost-effective additive manufacturing (AM) technologies, faces ongoing challenges in improving the dimensional accuracy and mechanical properties of complex shapes. The repeated heating and cooling of thermoplastic filaments make the FDM parts prone to accumulating warping deformation, which is difficult to predict due to the specificity of material deposition toolpaths. In this study, a path-based discrete modeling and process simulation method was developed for the FDM process. Based on process parameters and material deposition toolpaths, the finite element (FE) model was reconstructed using the discrete modeling method. Then, the birth-death element method (BDEM) was employed to simulate the FDM process and solve the thermo-mechanical coupling field in ANSYS 2022 R1. The corresponding computing programs were compiled in C++. The effectiveness of the proposed method was verified by three numerical examples using ABS material. According to the results, the simulated deformations show strong agreement with the deformations of real FDM parts. The findings of this study are applicable to other mainstream AM processes and are unrestricted by any complex geometries.