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<p>The development of numerical simulation software enables the modeling of complex physical phenomena that are difficult to detect in printed parts within the fused deposition modeling (FDM). However, simulating all possible combinations of process parameters, across factors and levels, remains time-consuming and computationally expensive. The use of numerical design of experiments (NDoE) is a relevant approach, as it enables the optimization and establishment of correlations between printing parameters and the associated physical phenomena. In this study, the influence of different printing temperatures (melting temperature, build-plate temperature, and ambient temperature) on polymer diffusion kinetics, filament coalescence (neck formation), and the resulting porosity is investigated numerically. The analysis is based on a two-dimensional numerical model that incorporates heat transfer and Schneider’s equations for crystallization simulation using multi-physics software. From these results, it is possible to evaluate filament coalescence, the degree of inter-filament healing, and interfacial porosity. Each parameter is analyzed separately to determine its individual influence on the phenomenon being investigated, and then the thermal interactions between these parameters are evaluated to better understand their combined effect on the physical mechanisms. The results indicate that higher build-plate temperatures, as well as prolonged exposure to processing ambient temperature, enhance inter-filament diffusion and reduce residual porosity. Moreover, changing the printing orientation from 0° to 90° leads to a significant increase in the degree of healing, rising from 0.55 to 0.71. In contrast, increasing the deposition temperature has only a limited effect on the initiation and development of these phenomena.</p>

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Multiphysics modeling of heat transfer, crystallization kinetics, and associated phenomena in the fused deposition modeling of polymers under varying processing parameters

  • 期刊论文

  • 发表日期：

    2026年5月5日

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  • Chihabeddine Khalil,
  • Youssef Hairch,
  • Anass Ben ayad,
  • Rabie El otmani,
  • M‘hamed Boutaous,
  • Khalid Kandoussi

摘要

The development of numerical simulation software enables the modeling of complex physical phenomena that are difficult to detect in printed parts within the fused deposition modeling (FDM). However, simulating all possible combinations of process parameters, across factors and levels, remains time-consuming and computationally expensive. The use of numerical design of experiments (NDoE) is a relevant approach, as it enables the optimization and establishment of correlations between printing parameters and the associated physical phenomena. In this study, the influence of different printing temperatures (melting temperature, build-plate temperature, and ambient temperature) on polymer diffusion kinetics, filament coalescence (neck formation), and the resulting porosity is investigated numerically. The analysis is based on a two-dimensional numerical model that incorporates heat transfer and Schneider’s equations for crystallization simulation using multi-physics software. From these results, it is possible to evaluate filament coalescence, the degree of inter-filament healing, and interfacial porosity. Each parameter is analyzed separately to determine its individual influence on the phenomenon being investigated, and then the thermal interactions between these parameters are evaluated to better understand their combined effect on the physical mechanisms. The results indicate that higher build-plate temperatures, as well as prolonged exposure to processing ambient temperature, enhance inter-filament diffusion and reduce residual porosity. Moreover, changing the printing orientation from 0° to 90° leads to a significant increase in the degree of healing, rising from 0.55 to 0.71. In contrast, increasing the deposition temperature has only a limited effect on the initiation and development of these phenomena.