Numerical investigation of the influence of process conditions on the temperature variation in fused deposition modeling

An adaptable three-dimensional transient mathematical model of temperature variation with respect to space and time, during and after the fused deposition modeling (FDM), is proposed and applied with a boundary-adjusting finite difference method. This model enables researchers to study the influence of almost all other parameters on the temperature field and gradient variation when constructing any cuboid at fixed raster angle of 0(90)degrees and filling ratio of 100%. Some predicted but significant conclusions are reached: reheating of a deposited raster by a newly deposited one is universal and happens mainly in the layer thickness direction; temperature settings are the primary and direct factors determining temperature field variation, while layer thickness and printing speed can still exert their own influence; printing speed is predicted to be positively correlated to mechanical properties of FDM constructed components through the mechanism of thermal coalescence; strict energy management is required if a FDM printer of higher resolution is to be invented and applied. The technique of such mathematical model can provide immediate insights in the understanding of FDM process from the perspective of energy balance, many of which have never been revealed from previous reports yet.