About this Abstract |
| Meeting |
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
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| Symposium
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2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
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| Presentation Title |
Computational Fluid Dynamics Modeling of Sequential Multi-Material Extrusion Additive Manufacturing |
| Author(s) |
Daniel Helmuth Meile, Carl Emil Hansen, Yohan Jacquet, Md Tusher Mollah, Berin Šeta, Jon Spangenberg |
| On-Site Speaker (Planned) |
Daniel Helmuth Meile |
| Abstract Scope |
Integrating multiple materials into extrusion-based additive manufacturing enables novel fabrication techniques and significantly expands the design freedom of the printed parts. However, multi-material extrusion remains a non-trivial task to implement, particularly due to the complex rheological behavior of the materials involved, influencing both the geometrical accuracy of the printed strand and the hardware requirements of the printing setup. A novel computational fluid dynamics (CFD) model has been developed, for simulating the dynamics of multiple material flows with differing rheological properties. Specifically, a scalar advection approach is used to modulate the rheology of the fluids during the extrusion and deposition of layers. To quantify and control the rheological difference between materials, a dimensionless number Y_RR representing the yield stress reduction ratio is introduced. This parameter enables systematic variation of yield stress between materials and serves as a critical factor in assessing interfacial deformation and print stability. The study investigates strand morphology and the dynamics of material switching, offering insights into how rheological mismatch and process parameters affect multi-material deposition. Overall, it provides a digital tool to better understand and optimize the complex flow phenomena inherent to multi-material extrusion additive manufacturing. |
| Proceedings Inclusion? |
Planned: Post-meeting proceedings |