IMPLEMENTATION OF NUMERICAL MODELING AND SIMULATION APPROACH FOR PERFORMANCE EVALUATION OF 3D PRINTING PROCESS IN BIOMEDICAL AND CONSTRUCTION APPLICATIONS

Abstract

Additive manufacturing (AM) or 3D printing (3DP) processes are gaining significant attention in different industrial sectors due to their substantial benefits over conventional manufacturing. However, the current practices in optimizing the structural design, material compositions, and 3DP process parameters involve extensive trial-and-error experimentations, which require significant resource consumption. Numerical modeling and simulation approaches can assist in sustainable exploration and performance prediction of AM processes. Therefore, the main aim of this thesis is to explore, adapt, implement, and validate sustainable numerical modeling and simulation approaches for performance prediction of 3D-printed structures. This thesis targets the performance evaluation of 3D-printed structures for two applications, i.e., biomedical and construction. The literature review on the topic assisted in identifying research challenges and, subsequently, the definition of research gaps, questions, and objectives for this research. The numerical modeling and simulation techniques were explored for performance prediction of AM processes, mainly material extrusion. Potential numerical modeling and simulation techniques were identified to mimic the polymeric and geopolymer materials in the extrusion process. Subsequently, numerical modeling and simulation approaches were implemented for performance prediction of the 3DP process for biomedical and construction materials. Finally, the effect of material properties and structural design on the 3D-printed structures was evaluated. The numerical modeling and simulation results provided a cost-effective alternative to conventional experimentation, making the technology more sustainable and environmentally friendly.

Date of Award	2023
Original language	American English
Awarding Institution	HBKU College of Science and Engineering