Flow analysis of the polymer spreading during extrusion additive manufacturing

Abstract The spreading of molten polymer between the moving printing head and the substrate in extrusion additive manufacturing is studied. Finite element computation and an analytical model have been used. The hypotheses of the analytical model are qualitatively justified by the results of the numerical computation. The analytical calculation is a powerful tool to rapidly evaluate the relationships between processing parameters (extrusion rate, printing head velocity, gap between the printing head and the substrate) and some characteristics of the deposition (dimensions of the deposited filament, pressure at the printing head nozzle, separating force between substrate and printing head). An isothermal hypothesis is discussed. The viscous non-Newtonian behavior is accounted for through an approximate shear thinning power law model. A printing processing window is defined following several requirements: a continuous deposit, without spreading in front of the printing head, maximum and minimum spreading pressures, an upper-limit for the separating force between head and substrate.