Numerical predictions and experimental validation on the effect of material properties in filament material extrusion

The numerical prediction of dimensional accuracy and mechanical performance of 3D-printed structures can eliminate or reduce the need to perform trial-and-error experimentation to achieve the desired part quality quickly and at a reduced cost. Therefore, this study focuses on experimental and numerical investigations of the effect of material properties on dimensional control of the material extrusion additive manufacturing process. A thermomechanical model is utilized, validated, and used to predict the part deflections, warpages, and residual stresses in 3D-printed components for two different materials (i.e., polyamide-6 (PA6) and acrylonitrile butadiene styrene (ABS)). In addition, numerical simulations for mechanical testing were performed and validated through experimental investigations. The numerical model considered the effect of material on final product quality and was in close agreement with experimental results. It was concluded that the materials with a lower thermal expansion coefficient (CTE) would provide better dimensional accuracy of 3D-printed parts. In addition, the lower thermal conductivity and temperature variations within the 3D-printed part will further produce precise parts. The controlled ambient environment using a closed chamber can also assist in maintaining desired thermal gradient and avoid non-uniform cooling during the process. Finally, the numerical model accurately predicted the mechanical behavior of 3D-printed samples as validated via experimentation.