Abstract
Purpose - The purpose of this paper is to systematically and critically review the literature related to process design and modeling of fused deposition modeling and similar extrusion based additive manufacturing or rapid prototyping processes.Design/methodology/approach - A systematic review of the literature was carried out focusing on process design and mathematical process modeling. Findings - Fused deposition modeling and similar processes are among the most widely used rapid prototyping processes with growing application in finished part manufacturing. Key elements of typical processes are described; including the material feed mechanism, liquefier and print nozzle, and the build surface and environment, along with approaches to part finishing. Approaches to estimating the motor torque and power required achieve a desired filament feed rate are presented. Models of required heat flux, shear on the melt, and pressure drop in the liquefier are reviewed. Upon leaving the print nozzle, die swelling and bead cooling are considered. Approaches to modeling the spreading of a deposited road of material as well as the bonding of polymer roads to one another are also reviewed. Originality/value - To date, no other systematic review of process design and modeling research related to melt extrusion additive manufacturing has been published. Understanding and improving process models will be key to improving system process controls as well as enabling the development of advanced engineering material feedstocks for fused deposition processes.
Purpose - The purpose of this paper is to systematically and critically review the literature related to process design and modeling of fused deposition modeling and similar extrusion based additive manufacturing or rapid prototyping processes.Design/methodology/approach - A systematic review of the literature was carried out focusing on process design and mathematical process modeling. Findings - Fused deposition modeling and similar processes are among the most widely used rapid prototyping processes with growing application in finished part manufacturing. Key elements of typical processes are described; including the material feed mechanism, liquefier and print nozzle, and the build surface and environment, along with approaches to part finishing. Approaches to estimating the motor torque and power required achieve a desired filament feed rate are presented. Models of required heat flux, shear on the melt, and pressure drop in the liquefier are reviewed. Upon leaving the print nozzle, die swelling and bead cooling are considered. Approaches to modeling the spreading of a deposited road of material as well as the bonding of polymer roads to one another are also reviewed. Originality/value - To date, no other systematic review of process design and modeling research related to melt extrusion additive manufacturing has been published. Understanding and improving process models will be key to improving system process controls as well as enabling the development of advanced engineering material feedstocks for fused deposition processes.