Finite element analysis of additive manufacturing based on fused deposition modeling: Distortions prediction and comparison with experimental data

Additive manufacturing (or three-dimensional (3D) printing) is constantly growing as an innovative process for the production of complex-shape components. Among the seven recognized 3D printing technologies, fused deposition modeling (FDM) covers a very important role, not only for producing representative 3D models, but, mainly due to the development of innovative material like Peek and Ultem, also for realizing structurally functional components. However, being FDM a production process involving high thermal gradients, non-negligible deformations and residual stresses may affect the 3D printed component. In this work we focus on meso/macroscopic simulations of the FDM process using ABAQUS software. After describing in detail the methodological process, we investigate the impact of several parameters and modeling choices (e.g., mesh size, material model, time-step size) on simulation outcomes and we validate the obtained results with experimental measurements.