Influence of process parameters on temperature field and residual strain in FFF-printed parts

Amongst the low-cost additive manufacturing processes available, fused filament fabrication (FFF) is one of the most widely used configurations not only for prototypes but also for functional components. Despite such extensive uptake, there are few comprehensive numerical tools available to aid in the design and structural optimization of components obtained with this technology. To address this shortfall, the present work embraces a methodology for thermal and structural simulation of the filament deposition process, with particular emphasis on the influence of process parameters and deposition strategy on the resulting residual stresses and distorsion to allow optimization of outcomes in terms of structural integrity and build accuracy. The developed finite elements simulation considers both material properties and process parameters, as well as environmental conditions. Comparison between simulation outcomes, thermal measurements and optical profiler acquisitions confirms good alignment, suggesting that such an approach is likely to prove valuable in improving process outcomes.