Research in 3D printing
Challenges and uncertainties hinder the adaption of AM technologies worldwide. Some of these important challenges are summarized in Fig. 1. These challenges include developing novel materials, predicting the performance and properties of printed components, predicting the effects of AM parameters on product specifications, NDT protocols, new advanced sensing and monitoring systems, and intelligent machine control.
Fig. 1. A list of some of the critical challenges of improving 3D printing technologies. Source: K.P. Dissertation
Among different AM technologies, FDM is fast-growing with diverse applications and significant potential for emerging from a prototype manufacturer to a fabricator of functional products. In addition, we want to develop a new method based on particularly designed testing artifacts to affordably and reliably address the improvement in quality and functionality of printed components by FDM. The objective of this research is defined to develop a combined experimental-numerical framework to systematically investigate relationships between process parameters and mechanical characteristics, geometrical characteristics, residual stresses, density, and bonding quality of 3D printed component by FDM. Through this process, we want to contribute to the promotion of FDM as a solution to 3D printing demands by:
development of an advanced computational framework to study the thermo-mechanical phenomena,
application of non-invasive optical methods for verification of numerical models and evaluation of 3D printed components,
design, characterization, and application of specific testing artifacts to improve our understanding of the complexity of FDM based on the framework.
Research topics and objectives in AM
Among different AM technologies, FDM is fast-growing with diverse applications and significant potential for emerging from a prototype manufacturer to a fabricator of functional products. In addition, we want to develop a new method based on particularly designed testing artifacts to affordably and reliably address the improvement in quality and functionality of printed components by FDM. The objective of this research is defined to develop a combined experimental-numerical framework to systematically investigate relationships between process parameters and mechanical characteristics, geometrical characteristics, residual stresses, density, and bonding quality of 3D printed component by FDM. Through this process, we want to contribute to the promotion of FDM as a solution to 3D printing demands by:
development of an advanced computational framework to study the thermo-mechanical phenomena,
application of non-invasive optical methods for verification of numerical models and evaluation of 3D printed components,
design, characterization, and application of specific testing artifacts to improve our understanding of the complexity of FDM based on the framework.
Fig. 2. list of some of the critical parameters in different 3D printing technologies. Source: K.P. Dissertation
Significance of AM research
Assessing multifaceted effects of fluidic, thermal, mechanical, micro-structural, and meso-structural on characteristics of a 3D printed components is crucial to our understanding of different technologies. Because of complexity and nature of the multi-physics problem these effects mostly were addressed individually or in a combination of thermal with mechanical strength or thermal with dimensional tolerances. It is crucial to develop and apply research tackling these convoluted problems.
In addition, it is necessary to incorporated numerical simulations of thermo-fluidic-mechanical effects with experimental validations. From this perspective, this unique approach leads to a reliable understanding of thermo-mechanical effects and offers promising improvements such as reliability, simplicity, verifiability, versatility, and effectiveness.
Fig. 3. Even the simplest AM technology such as FDM/FFF different physics involved. Source: K.P. Dissertation
Research can develop practical computational solutions that not only imitated the realistic manufacturing procedure in a layer-by-layer fashion but also improved modeling efforts. Developed solutions may be realized by tuning and adjusting the assumptions in simulations in the presence of experimental data. Such an approach addresses essential factors in different technologies. in FDM technologies the following list is among the one can be reached:
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effects of the thermal and structural contact between platforms and heated-bed;
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validated coefficient of heat transfer;
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radiation heat transfer;
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temperature dependent material properties such as yield stress, ultimate strength, module of elasticity, convection heat transfer coefficient, and radiation heat transfer;
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phase transmission heat effects;
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bonding and neck growing;
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spatially and temporally varying conductivity;
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plastic thermo-mechanical deformation.