Numerical modelling of the warping behaviour at the first layer-build plate interface in 3D-printed models produced via the fused deposition modelling process

Abstract

The material structure of 3D-models printed via the fused deposition modelling (FDM) technique is mainly affected in the z-direction of the 3D-print as a result of the layer-by-layer approach which tend to exhibit a deformation behavior corresponding to a type of transversely orthotropic material. Moreover, uncontrolled parameters such as printing temperature and printing speed have been reported to adversely affect 3D-print quality leading to undesired effects such as distortion and warpage. The additive manufacturing process is a relatively new field in advanced manufacturing where further research and innovation are required to overcome the limited strength and structural performance observed in presently 3D-printed components. In line with the above, this study proposes the numerical investigation of the warping behavior in PLA (Polylactic acid) - based 3D printed models by considering the finite element method (FEM) software of LS-DYNA. The warping investigation was specifically centered on the cooling cycle prevailing between the layer-by-layer structures. The findings of this study showed that warpage would most likely occur in the thermal process model corresponding to abrupt change in temperature due to a buildup of strain between the bottom most layers of the 3D model and the build plate. The findings of this study, which shed light on the warping behaviour in 3D-models, has direct implications on the final quality of 3D-printed components.