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From Deposition Sequence to Mechanical Response: A Macroscale Process Simulation of Material Extrusion

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Abstract:

The deposition sequence and the resulting thermal history govern the development of distortions and residual stresses in components made by material extrusion, ultimately affecting their structural performance. This work presents a process-aware thermomechanical simulation framework that reproduces the actual deposition directly from the G-Code. The nozzle trajectory is processed to reconstruct the bead order and timing and to automatically generate a voxel-based finite element mesh suitable for progressive activation. A transient thermal analysis is then performed with incremental element activation, while the thermal effect of extrusion is prescribed through a temperature predefined field applied to the newly activated elements, together with convective-radiative heat losses to the environment. The resulting temperature history is subsequently transferred as a time-dependent temperature field to a quasi-static mechanical analysis to predict residual distortions and stresses after cooling. Finally, a linear elastic virtual tensile test is carried out on the final, deformed configuration, accounting for the residual stress state. The framework is applied to PLA ASTM D638 specimens manufactured at different extrusion temperatures and validated against experimental tests, showing that extrusion temperature governs thermal gradients, residual stress distributions and the resulting macroscopic elastic response.

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Periodical:

Defect and Diffusion Forum (Volume 451)

Pages:

111-123

DOI:

https://doi.org/10.4028/p-FW1Rb0

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Cite this paper

Online since:

April 2026

Authors:

Mario Emanuele Di Nardo*, Pietro Russo, Pierpaolo Carlone

Keywords:

Additive Manufacturing, FEM, FFF, MEX, Process Simulation, Thermomechanical Analysis

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Creative Commons CC BY 4.0

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* - Corresponding Author

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