Process optimization of large scale robot based polymer 3D printing

Reference number 2018-04342
Coordinator RISE IVF AB - Avdelningen för Tillverkning
Funding from Vinnova SEK 500 000
Project duration November 2018 - November 2019
Status Ongoing
Venture Banbrytande idéer inom industriell utveckling
Call Banbrytande idéer inom industriell utveckling 2018

Purpose and goal

This project aims at developing a computational fluid dynamic model for large-scale robot-based additive manufacturing in order to: 1- determine temperature history over the entire cross section of the deposited material, 2- predict thermal residual stress, deformation and distortion resulting from temperature gradients and crystallization of the thermoplastic polymer. 3- estimate the final shape of deposited filament after cooling to ensure maximum bonding area between the layers. 4- evaluate effect of reinforcement fibers on the structural integrity of composite parts.

Expected results and effects

Printing failures including distortions, gaps, voids, and cracks are very common in printed polymer parts. Therefore, development of a novel modeling strategy to predict these failures and capture various process parameters in large-scale robot-based additive manufacturing is of critical importance. The developed model can prevent warpage and cracking, and help enhance mechanical strength and structural integrity of printed parts. This, finally, can facilitate commercialization of large-scale polymer printing.

Planned approach and implementation

A computational fluid dynamic model will be developed to simulate the entire process of 3D printing including heating, deposition, and cooling in a layer-by-layer manner. The influence of important process parameters including melt temperature, layer thickness, and printing speed will be investigated using the model. The change of thermal stress, deformation and temperature with time will be evaluated in detail. The numerical results will be verified by experimental measurement of temperature and distortion.

The project description has been provided by the project members themselves and the text has not been examined by our editors.