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CFD Simulations and Experimental Analysis of Bubble Nucleation and Growth in Foam Additive Manufacturing (FAM)
Foam Additive Manufacturing (FAM) integrates 3D printing with physical blowing agents (PBAs) to produce lightweight, porous structures. The extrusion process, which involves a polymer-PBA solution, is critical for foam formation [1]. Bubble nucleation and growth occur due to rapid pressure drops and temperature changes within the extruder nozzle.
Keywords: Printing, FDM, Foams, plastics, Additive Manufacturing, AM
This project aims to improve the understanding of bubble dynamics by combining computational fluid dynamics (CFD) simulations with in situ experimental visualization. High-speed cameras will capture polymer and bubble flow dynamics, providing data to validate CFD models. The ultimate goal is to optimize FAM process parameters for tailored foam structures with controlled morphologies [2].
This project aims to improve the understanding of bubble dynamics by combining computational fluid dynamics (CFD) simulations with in situ experimental visualization. High-speed cameras will capture polymer and bubble flow dynamics, providing data to validate CFD models. The ultimate goal is to optimize FAM process parameters for tailored foam structures with controlled morphologies [2].
The project will focus on the following high-level goals:
• Develop CFD models to simulate polymer and bubble flow in the extruder nozzle.
• Use experimental in situ visualization to validate simulation results.
• Investigate the effects of key extrusion parameters (temperature, speed, and nozzle diameter) on bubble formation and the consequent foam morphology.
The project will focus on the following high-level goals: • Develop CFD models to simulate polymer and bubble flow in the extruder nozzle. • Use experimental in situ visualization to validate simulation results. • Investigate the effects of key extrusion parameters (temperature, speed, and nozzle diameter) on bubble formation and the consequent foam morphology.
CFD_FoamPrinting.pdf
