Simulation of a 3D printing process

Abstract

The aim of this report is to present an overview of the work done by Iñigo Urcelay Oca during his internship at the Institut für Faserverbundleichtbau und Adaptronik, Strukturmechanik, DLR, in Braunschweig. The report indicates as well what the following steps should be in order to continue the work presented. The report starts with a brief description of the manufacturing process, Fused Deposition Modelling (FDM), and the characteristics of the material, semi-crystalline thermoplastic PLA. It is followed by a brief overview of the state of the art regarding the simulation of FDM for different types of materials. Then the work done regarding the modelling on Abaqus is explained in detailed, so that in conjunction with the comments on the scripts, the procedure that was followed and the decisions that were made can be clearly understood. Other possible tools were also researched. An evaluation of AlphaStar software, as well as a description of its characteristics, can be found next in the report. The results obtained from the scripts written by the author are then presented, describing the convergence issues and the strategies followed to try to solve them. The results from the experimental tests are also shown. The report ends with the author presenting the conclusions resulting from the work done, as well as the next steps to be followed in order to continue it.