Fully resolved numerical simulations of fused deposition modeling. Part I: fluid flow

Purpose: This paper aims to present a first step toward developing a comprehensive methodology for fully resolved numerical simulations of fusion deposition modeling (FDM). Design/methodology/approach: A front-tracking/finite volume method previously developed for simulations of multiphase flows is extended to model the injection of hot polymer and its cooling down. Findings: The accuracy and convergence properties of the new method are tested by grid refinement, and the method is shown to produce convergent solutions for the shape of the filament, the temperature distribution, contact area and reheat region when new filaments are deposited on top of previously laid down filaments. Research limitations/implications: The present paper focuses on modeling the fluid flow and the cooling. The modeling of solidification, volume changes and residual stresses will be described in Part II. Practical implications: The ability to carry out fully resolved numerical simulations of the fusion deposition process is expected to help explore new deposition strategies and provide the “ground truth” for the development of reduced-order models. Originality/value: The present paper is the first fully resolved simulation of the deposition in fusion filament modeling.