Additive manufacturing (AM) has drawn interest from fields ranging from aerospace to regenerative medicine to metamaterials. Using AM, specimens with complex internal geometries and structures can be manufactured. Despite the advantages and interest, broader use of AM is limited by poor mechanical properties, lack of reliability, and lack of expertise. In this presentation, I will describe a finite element model we developed to simulate heat transfer and generate temperature profiles during material extrusion AM (MatEx). At benchtop (FFF) scales, short times over Tg were reported, indicating limited opportunity for interlayer diffusion. Additionally, maxima in cooling rates were observed at print speeds of 10-30 mm/s, which may have implications for residual stress formation. At larger (BAAM) scales, much longer times above Tg were observed, which can lead to continued flow of extruded material and warping of the printed structure. The effects of material and processing parameters were investigated at both scales, and different trends were observed at the small and large scales. I will also present preliminary modeling addressing the importance of geometry and toolpath design. Combined, these results indicate that designing MatEx materials and processes in concert will lead to improved structure performance, and give preliminary guidance in development of design rules.

Thermal modeling and bead parameterization of material extrusion additive manufacturing from FFF to BAAM

Macromolecular Chemistry: The Second Century

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ACS Spring 2020 National Meeting & Expo

The official archive and repository for all ACS Meetings & Expositions abstracts and select posters or presentations.