Assessing nozzle flow dynamics in fused filament fabrication through the parametric map α − λ

Journal article (2024)

Authors

Tomás Schuller Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), Universidade do Porto
P. Fanzio Micro and Nano Engineering - Mechanical, Maritime and Materials Engineering
Francisco J. Galindo-Rosales Universidade do Porto
Research Group
Micro and Nano Engineering (Mechanical, Maritime and Materials Engineering) (TU Delft)
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Published Date

2024

Language

English

Reuse Rights

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Faculty

Mechanical, Maritime and Materials Engineering

Department

Precision and Microsystems Engineering

Research Group

Micro and Nano Engineering

Abstract

Polymer rheology profoundly influences the intricate dynamics of material extrusion in fused filament fabrication (FFF). This numerical study, which uses the Giesekus model fed with a full rheometric experimental dataset, meticulously examines the molten flow patterns inside the printing nozzle in FFF. Our findings reveal new insight into the interplay between elastic stresses and complex flow patterns, highlighting their substantial role in forming upstream vortices. The parametric map α-λ from the Giesekus model allowed us to sort the materials and connect the polymer rheology with the FFF nozzle flow dynamics. The identification of elastic instabilities, the characterization of flow types, and the correlation between fluid rheology and pressure drop variations mark significant advancements in understanding FFF processes. These insights pave the way for tailored nozzle designs, promising enhanced efficiency and reliability in FFF-based additive manufacturing.