Register now After registration you will be able to apply for this opportunity online.
Numerical Simulation of Polymer 3D Printing Process
The Advanced Manufacturing Lab (am|z) is a leading hub for innovative research in advanced manufacturing and materials processing technologies, with a particular focus on advancing 3D printing processes in metals and polymers. The goal of this thesis project is to develop a numerical model for the Fused Deposition Modeling (FDM) 3D printing process. The model will be developed using the commercial finite element solver COMSOL Multiphysics. To ensure its accuracy, the numerical model will be validated against existing experimental data.
Keywords: Finite element method, 3D printing, Fuse deposited modeling, Manufacturing process
Lightweight structures with high performance are typically created using composite materials reinforced with fibers. However, the fabrication of these structures is resource-intensive in terms of energy and labor, and it is mostly limited to basic geometries and reinforcement patterns. Modern 3D printing techniques now allow to produce components with complex geometries and intricate reinforcement patterns. Recent research suggests that aligning polymers during fused deposition modeling (FDM) can result in parts with complex microstructures adapted to specific loads [1]. In FDM, thermoplastic filaments are fed from a large spool through a heated printer extruder head, moving along predefined paths to build the desired structure - see Figure 1A for a schematic representation. Achieving the desired properties in the final product requires process optimizations such as feed rate, temperature, and nozzle speed. The high cost and time required to experimentally optimize these parameters underscores the importance of numerical modeling. Such a model could serve as a valuable optimization tool, providing a more efficient and cost-effective means of refining these parameters [2]. The intricate nature of modeling the FDM process, which involves complex physics such as thermal and mechanical interactions with multi-phase participation (both solid and liquid phases), requires a more thorough investigation than currently exists.
In this thesis project, the student's primary objective is to enhance the existing FDM process model, with a particular focus on overcoming its current limitations in terms of experimental validation and simulation capabilities. The current model, which is characterized by slow performance and the ability to handle only simple geometries, requires refinement to enable simulations involving more complex geometries. The exploration of adaptive meshing techniques is proposed to accelerate the model run time.
Furthermore, a critical aspect of the project is to investigate the effects of reheating within the FDM process. The overall goal is to significantly improve the accuracy of the model and expand its applicability by systematically addressing these specific challenges.
Lightweight structures with high performance are typically created using composite materials reinforced with fibers. However, the fabrication of these structures is resource-intensive in terms of energy and labor, and it is mostly limited to basic geometries and reinforcement patterns. Modern 3D printing techniques now allow to produce components with complex geometries and intricate reinforcement patterns. Recent research suggests that aligning polymers during fused deposition modeling (FDM) can result in parts with complex microstructures adapted to specific loads [1]. In FDM, thermoplastic filaments are fed from a large spool through a heated printer extruder head, moving along predefined paths to build the desired structure - see Figure 1A for a schematic representation. Achieving the desired properties in the final product requires process optimizations such as feed rate, temperature, and nozzle speed. The high cost and time required to experimentally optimize these parameters underscores the importance of numerical modeling. Such a model could serve as a valuable optimization tool, providing a more efficient and cost-effective means of refining these parameters [2]. The intricate nature of modeling the FDM process, which involves complex physics such as thermal and mechanical interactions with multi-phase participation (both solid and liquid phases), requires a more thorough investigation than currently exists. In this thesis project, the student's primary objective is to enhance the existing FDM process model, with a particular focus on overcoming its current limitations in terms of experimental validation and simulation capabilities. The current model, which is characterized by slow performance and the ability to handle only simple geometries, requires refinement to enable simulations involving more complex geometries. The exploration of adaptive meshing techniques is proposed to accelerate the model run time. Furthermore, a critical aspect of the project is to investigate the effects of reheating within the FDM process. The overall goal is to significantly improve the accuracy of the model and expand its applicability by systematically addressing these specific challenges.
The objectives of this project are as follows:
I. Extend the existing model to represent a more realistic FDM process.
II. Perform experimental validation of the current model to ensure its accuracy and reliability.
III. Refine the model to allow simulation of more complex geometries.
IV. Implement and study the effects of the reheating process within the FDM simulation.
The objectives of this project are as follows: I. Extend the existing model to represent a more realistic FDM process. II. Perform experimental validation of the current model to ensure its accuracy and reliability. III. Refine the model to allow simulation of more complex geometries. IV. Implement and study the effects of the reheating process within the FDM simulation.