Simulate 3d printing

Deformation

Assuming that the true mechanical properties of the material are known, the deformation of the part during manufacture can be calculated.

The direction of the deformation are usually correct no matter what simulation parameters are used, but the amplitude of the deformation is closely dependent on the size of the simulation mesh: using a finer mesh will yield more precise results, but requires more time to run.

Deformation vectors of a model (SLM/DMLS) in Netfabb. Courtesy Poly-Shape

Recoater interference

In powder bed technologies (such as SLS and SLM/DMLS), if the deformation along the z-axis is larger than the layer thickness, the recoater can come in contact with the part, sweeping it away and causing a failure. In some simulation packages, you can define the height of the recoater tolerance and the software will warn you in case a deformation along the z-axis exceeds that threshold.

Post processing steps

The primary focus of the 3D printing simulation packages is the computation of thermo-mechanical phenomena occurring during the fabrication of a part. However, other problems can also appear in later steps of the manufacturing process.

During the detachment of the part from the build platform or the removal of the support structures, the residual stress from the manufacturing process can cause the part to deform. Heat treatments can help relieve the internal stress. Some simulation packages allow you to simulate these post-processing steps and help evaluate whether a heat treatment is necessary (or even effective).

List of simulation software

Discretization

The first step of a good simulation is the correct discretization of the part volume.

Unlike regular mechanical simulation, which uses conformal meshing with tetrahedrons, most 3D printing simulation software use voxelization. the 3D volume of the part is represented by small cubes (or voxels), in a similar way that a 2D image in a PC monitor is represented by square pixels. Using more meshing elements produce more precise results, but also increases significantly the simulation time. Finding the right balance is key.

For an initial simulation, it can be interesting to launch a first coarse simulation, with large voxels, in order to obtain “quick and dirty” results. Such a simulation should enable you to obtain in a matter of seconds or minutes the main deformation areas of your print. It will not cost you much and can help you decide if a more precise simulation (with smaller voxels) is necessary.

Material & print parameters

Once the part is discretized, you need to select the material properties. Defining the material properties is probably the most crucial step in the simulation process, as inaccurate data will produce wrong simulations results.

Most editors provide their own material library, which can be really helpful to get you started.

In both cases, they are probably not perfectly adapted for simulations. Every simulation software allows you to modify or create your own materials to generate the most accurate simulations. This requires expert material science knowledge to be done correctly and it is not recommended for inexperienced users.

Calibration

Some simulation software allows you to calibrate the material properties based on test specimens printed in a specific material and on a specific machine. This way, more precise material properties are identified, resulting in more accurate simulation results.

Key steps for a successful simulation

There are two types of simulation software: cloud based solvers and local solvers.

Cloud based solvers are usually faster than local solvers, as they are not restricted by the computational capabilities of your computer. However, some companies are reluctant to use cloud based solvers due to confidentiality issues, as data sent through the Internet could be more easily compromised. For most application this would not be an issue.

Here is a list of some of the most popular 3D printing simulation software:

Rules of Thumb

• Simulate before support generation to improve part geometry and to aid with the design of supports.
  
• Simulate after support generation to validate accuracy and to check for recoater interference.
  
• First run a quick simulation with large voxels to identify areas of larger deformation. Then refine the mesh to improve accuracy of the results.
  
• Simulate temperature without mechanical resolution to save time, as solving the heat accumulation issues might also solve mechanical deformation problems.
  
• Prefer cloud based simulation software for faster performance, but use local solvers if needed to comply with confidentiality policies.

Essential Bonus: Download for free the Design Rules for 3D printing poster in high-resolution, full of actionable guidelines for the 6 major 3D printing processes.

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JULY 2022

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Ansys 2022 R2 expands toolsets for Additive Manufacturing Users, streamlining your workflows between design, simulation, and manufacturing. Every Ansys Mechanical User can now identify and minimize the risk for build errors and ensure high-quality parts through process simulation for Metal Laser Powder Bed Fusion (LPBF), Directed Energy Deposition (DED), and Metal Binder Jet (MBJ).

• Workflow Improvements
  • Automatic Distortion Compensation is the ability to optimize a distortion compensated model within a simple automated workflow, which improves first-time print success.  
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Imitation of wood texture in 3D printing.

Papa Carlo Method

In the past year, printouts made of wood-filled plastics were laid out from time to time. Here are a couple of interesting works:

These plastics are designed to imitate wood when printed. But printouts are still more like chipboard.

Very plausible end caps for a wooden staircase turned out by comrade eduardo:

Due to the alternation of temperature on different layers with a change in color, a texture was obtained that resembles the annual rings of a tree. nine0003

It turns out that in order for the printout to look like a real tree, you need plastic in two colors (light and dark annual rings). And it would be more logical to draw these annual rings in the model itself than to try to get them by changing the printing temperature.

We are trying to depict a product carved from wood. And why not take and draw, as plausibly as possible, a log with its structure of annual rings. And already from the log cut out any Pinocchio we need. This is, of course, a tortuous path, but it promises us an interesting result. nine0003

Let's start drawing in Solid Works. I looked a little at how the tree cuts look like:

And I started drawing my sketch:

When drawing, it is better to avoid splines and replace them with arcs, otherwise the program may start to desperately slow down.

From this sketch, extrude the boss along the path. We take a slightly curved line as a trajectory:

It would be possible, of course, to use an ordinary elongated boss, but then the pattern will turn out to be unnaturally straight when cut. nine0003

The result is a part of the log, consisting of light rings:

We extend the dark annual layers using the same boss along the path.

At the same time, we use the sketches of the profile and the trajectory from the previous boss (with light rings).

To do this, you need to make them available. You need to right-click on the thumbnails and select “display” (points):

When extruding the boss, select the areas not occupied by light layers. And an important point. You need to uncheck the "combine results" checkbox:

Otherwise, all layers will merge into a single cylinder.

Now we have the same log of light and dark layers, with each layer being a separate body:

Now we can cut any shape out of the log using cutouts.

If you use a regular elongated cutout, you can get a board and even make a sign on it:

Or a dice:

If you use a rotated cutout, you can get rotation figures:

In principle, you can create absolutely any figures using operations subtraction. nine0003

The woodgrain effect opens up a wide range of applications. Similarly, you can create models for phone cases, various devices, and even inserts in car dashboards. And everything related to the car can be very promising in terms of modeling and printing to order. Some people love cars more than their wives.

But to print dual color models, you will need a dual print head printer with good print quality, such as the ULTIMAKER 3.

But the vast majority own printers with a single print head. Shouldn't it be applied already?

If you are not afraid of post-processing, then you can get by with an ordinary one-eyed Chinese.

I'll show you how:

Let's create something useful... For example, a handle for a door or for a checkpoint.

Like this (one rotated log cutout):

Now let's remove the dark annual rings (bodies) from the model and fill in the resulting voids at a distance of 1 mm from the surface (using a rotated boss):

Save in STL format, slice, print with supports (beige PLA REC):

Now fill the grooves with PLA juice from plastic of a different color. Personally, I smeared with a screwdriver. It is desirable to make the consistency thicker in order to reduce shrinkage after drying. Or we fuse plastic with a 3D pen. PLA juice has the advantage of being able to more accurately match colors by incorporating multiple colors of plastics into the solution. I came up with such a nightmare:

After the PLA juice dries, we grind off everything superfluous. For the convenience of grinding, I provided a socket for a bit for a nozzle on a screwdriver. Wet the surface with DXM with a brush to shine:

The result is certainly not ideal. Here you can also refine the model of the log itself for greater realism, add a varnish coating with the desired shade. Also, the use of wood-filled plastic would add naturalism. But in general, in my opinion, it turned out well. Something reminiscent of the texture of pine. By the way, PLA juice after solidification contains a lot of bubbles in the mass, which also adds a sense of porous structure.

Using this approach, you can create such models in other programs. nine0003

Door handle model here: http://3dtoday.ru/3d-models/for-home/kitchen/dvernaya_ruchka_pod_derevo/

Bye everyone! Take care of yourself and your loved ones.

#Contest_Ultimaker

3D printing with epoxy composites can mimic the properties of cork material

Archive

-curable polymers, but now scientists from the Harvard School of Engineering and Applied Sciences have teamed up with the Wyss Institute of Bioengineering to create an epoxy-based thermosetting polymer for 3D printing. These epoxy composites allow printing with materials that are used as structural components for lightweight structures. These new 3D materials consist of epoxy resins combined with nanoclay particles to increase viscosity and a dimethyl methylphosphonate compound. To this mixture are added two fillers, silicon carbine and carbon fibers. nine0003

The orientation of these fillers in the media determines the versatility and strength of the printed material. This blend is a composite whose strength and stiffness can be adjusted and is approximately 200% stronger than the best printed resin composites currently available. The description of the study was published in the article "3D printing of lightweight cellular composites" in an issue of the journal Advanced Materials, co-authored by Brett Compton and Jennifer Lewis. nine0003

Epoxy 3D printing of cellular structures. In the right image, you can see how the fibers align as they pass through the extruder nozzle.

Lorna Gibson, Professor of Materials Science and Engineering at the Massachusetts Institute of Technology explained the significance of this research:

“This paper demonstrates for the first time 3D printing of cellular structures with fiber-reinforced cell walls. Of particular importance is that the fibers can be aligned by controlling the ratio of parameters such as fiber length to fiber diameter and nozzle diameter. This marks an important step forward in the development of building materials that mimic wood. ” nine0103

Why is it so important to imitate wood in this way? After all, we have wood, right?

The main potential for using this material is to create structural honeycombs that will serve as core inside wind turbine blades. Currently, these blades are filled from the inside with compressed building materials, one of which is cork wood. Despite the fact that balsa (cork tree) is considered a fast-growing tree and belongs to a rapidly renewable resource, its wood has small variations, due to which it can be quite difficult to choose exactly the one that fully meets the requirements established for such products. In addition, balsa wood is a relatively expensive material, and as the length of the blades used in these wind turbines increases, some of which are already about 250 feet long today, the cost and the need for precision also increase. Using this material and 3D printing technology, researchers have been able to create cellular composite materials that are superior to balsa wood in terms of properties. nine0003

But this material could be used for more than just wind turbines, as fuel efficiency requirements in the automotive industry are becoming ever more stringent, a strong and lightweight material like this could be exactly what will help designers build ever better cars, conforming to these standards.

Compton sees the future use of this epoxy composite as follows:

“Because we have been able to achieve additional levels of control in filler alignment and learn how to better integrate these directional fibers into component design, we can further optimize component design to improve material performance. Eventually, we will be able to use 3D printing technology to change the degree of fiber alignment and local composition on the fly.” nine0103

Various cellular structures 3D printed from epoxy carbon fiber composites and conductive properties.

What other applications could this material be used for? Share your opinion in the comments to this article.

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