Project Details
Projekt
Advanced understanding of melting and flow mechanisms in the nozzle of an FFF-printer
Subject Area
Plastics Engineering
Measurement Systems
Primary Shaping and Reshaping Technology, Additive Manufacturing
Measurement Systems
Primary Shaping and Reshaping Technology, Additive Manufacturing
Term
since 2024
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 545960701
Additive manufacturing is a relatively new manufacturing technology known primarily for its nearly boundless design capabilities. Initially used for rapid prototyping and smaller quantities, various processes have undergone improvements marking initial steps toward serial production. Fused filament fabrication stands out as one of the most commonly employed additive manufacturing methods, utilizing plastic filaments that are melted and deposited onto a print bed through a portal system. As with other manufacturing technologies, modeling and simulation are commonly employed techniques to minimize waste and increase production rate. However, this necessitates a thorough understanding of the processes occurring within the nozzle. This has lead to a handful of studies presenting methods to analyze the melt and flow behavior of molten plastic, e.g. using either a glass nozzle for melt observation and CT-analysis on cooled filament strands. Unfortunately, both approaches fall short in replicating real-world processes and cannot be fully applied to metallic nozzles. In the presented proposal, an in-situ-CT-analysis will be conducted using an experimental setup. By adding tungsten particles to a pure plastic filament, insights into the melt and flow behavior can be obtained through the interaction between the particles and X-ray radiation. Two different experiments will be conducted to investigate the influence of tungsten particles on flow behavior and thermal properties. Fine and homogeneously distributed tungsten particles are necessary to visualize the plastic in the CT analysis, while larger particle diameters are advantageous for particle image velocimetry. Combined with a setup designed to be as X-ray transparent as possible, this approach aims to gain additional insights into material behavior during extrusion. Additionally, this will allow for the verification of existing and future model assumptions in simulations using realistic experimental values.
DFG Programme
Research Grants
