SIM-AM 2025

On Numerical Simulation for Non-Planar 3D-Printed Components Including Anisotropy

  • Tröger, Jendrik-Alexander (Clausthal University of Technology)
  • Ewougsi Tekeu, Christian-Lionel (Clausthal University of Technology)
  • Afshari, Arash (Clausthal University of Technology)
  • Inkermann, David (Clausthal University of Technology)
  • Hartmann, Stefan (Clausthal University of Technology)

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Conventional material extrusion 3D-printing produces components by depositing planar layers of the material under consideration. This planar printing process is burdened with inferior mechanical properties and weak interlayer bonding, limiting the applicability of 3D-printed polymer components. To address these challenges, non-planar or spatial printing procedures have been developed, allowing layers to be oriented in three dimensions. Exceptional mechanical properties have been reported for non-planar printing, see [1] for an exemplary work among others. The non-planar printing process hinges on optimizing the print trajectory, which necessitates integration of accurate and flexible numerical simulations. Such simulations are crucial for optimizing the print trajectory and even the topology of 3D-printed components. Current works dealing with simulation of non-planar printed components often do not take into account the anisotropy resulting from the layer-wise procedure. Significant model errors could be introduced, especially when assuming linear isotropic elastic material in the numerical simulations, see, for example, [2]. To overcome these limitations while maintaining a flexible simulation approach, we propose a novel framework for the numerical simulation of non-planar 3D-printed components using finite element simulations. Our approach incorporates orthotropic material behavior to accurately represent the spatially anisotropic nature inherent in additively manufactured parts. We leverage G-code data as flexible modeling approach to capture anisotropy in terms of printing and building direction. By performing continuous interpolation of the G-code data, we compute locally varying preferred directions of orthotropy. The developed approach is not restricted to but particularly suited for non-planar printed components. The effectiveness of the proposed method is demonstrated through numerical examples including both planar and non-planar print trajectories. References [1] Fang, G., Zhang, T., Huang, Y., Zhang, Z., Masania, K., Wang, C. Exceptional mechanical performance by spatial printing with continuous fiber: Curved slicing, toolpath generation and physical verification. Addit. Manuf. (2024) 82:104048. [2] Guidetti, X., Balta, E. C., Nagel, Y., Yin, H., Rupenyan, A., Lygeros, J. Stress flow guided non-planar print trajectory optimization for additive manufacturing of anisotropic polymers. Addit. Manuf. (2023) 72:103628.