Computational and Experimental Characterization of 3D Printed Components by Fused Deposition Modeling

This paper presents the development of methodologies to understand the effects of process parameters in 3D printed components' performance and geometrical characteristics, specifically distortions and residual stresses. Full-field-of-view noninvasive optical metrology methodologies and computational simulations outline the framework of this approach. We are developing computational models to predict the critical attributes of 3D printed parts by Fused Deposition Modeling (FDM). We are also designing particular testing artifacts with specific shapes and geometries to conduct Non-Destructive Testing (NDT) using full-field-of-view optical sensors, i.e., Digital Holographic Interferometry, Digital Image Correlation, and Digital Fringe Projection. These sensors can be utilized during and after fabrication for extraction of mechanical properties, identification of defects, and characterization of geometrical accuracies/distortions as a function of process parameters. The knowledge gained from NDT results is used for tuning our computational models. Representative results demonstrate the feasibility of the proposed computational-experimental approach for potential implementation into FDM processes in order to understand the interconnection between process parameters and part performance, which eventually will lead to improvements in the integrity, repeatability, and consistency of printed components and to reduced costs and optimized energy consumption.