
Sensitivity Analysis of Fusing and Detailing Agent Effects on Polymeric Component Temperature Using Numerical and Experimental Models (Sim-AM 2025)
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As additive manufacturing (AM) advances, the need for rapid processes capable of producing high-fidelity components with broad material versatility becomes critical. Multi Jet Fusion (MJF), a powder bed fusion technology for various thermoplastic materials, has recently emerged to meet these demands. This study develops a numerical simulation of MJF by considering the effects of fusing and detailing agents to identify the process temperature and their impact on the crystallinity of the components. By varying the preheat temperature and absorptivity of the agents, the sensitivity of the developed simulation tools was analysed. Different samples were printed using MJF technology, and the process was simulated alongside the experimentation. In the next step, the preheat temperature and absorptivity values were varied according to the Design of Experiments (DoE), and the process temperature was captured through simulation. The temperature was converted to crystallinity and compared to the experimental values for verification. Statistical analyses, such as multivariate analysis of variance including F-Values and P-value analyses, were applied to identify the effects of preheat and liquid agents on the results. Adjusting the absorption ratio influences local temperatures, mimicking the chemical behavior of commercial agents. The multivariate analysis of variance for absorption ratio and preheat temperature yielded p-values far below 0.05, indicating a predictive accuracy of up to 98% and highlighting their significant impact on maximum agent temperatures. This study presents the first simulation of MJF by considering the combined effects of fusing and detailing agents for polymeric parts. The research offers novel numerical and analytical models to predict the MJF process temperature and details the impact of different agents on the absorptivity of the powder particles when exposed to IR lamps. This project has been successfully completed to design and enhance safety components using MJF technology for Ford Motor Company. The improvements aim to ensure higher safety standards and better performance in the automotive industry.