Finite Element Modeling of an Optimized Liquefier Design for 3D Printing of CFRTPCs by Thermal Simulation

Abstract

This paper aims to propose a design of 3D printer liquefier for continuous fiber reinforced thermoplastic composites (CFRTPCs) by analyzing the performance of its thermal behavior. This new liquefying system is based on the design of the widely commonly used RepRap E3D V6 extruder. The proposed heating system considers the optimization of wire feeding mechanism and fan energies, durability of the 3D printing (3DP) machine and the quality of the process. Thus, the resulted design consists of the main components of E3D V6 extruder and two other parts with relevant shape. This latter ensure the appropriate mixing of polymer/fiber and the vehicling of the both materials simultaneously through the hot end. In particular, this work focuses on the temperature distribution of polylactic acid (PLA) material and its optimum fabrication conditions reinforced by carbon fibers. A parametric study of material and shape was conducted and was led to the final design. The implemented finite element model (FEM) is useful for similar designs with the same working principles.