VOLCO: A predictive model for 3D printed microarchitecture

Material extrusion additive manufacturing is widely used for porous scaffolds in which polymer filaments are extruded in the form of log-pile structures. These structures are typically designed with the assumption that filaments have a continuous cylindrical profile. However, as a filament is extrud...

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Main Authors:	Andy Gleadall, Ian A. Ashcroft, Joel Segal
Format:	Default Article
Published:	2018
Subjects:	Mechanical engineering not elsewhere classified 3D printing 3D geometry modelling Finite element analysis Voxel model Tissue engineering scaffolds Mechanical Engineering not elsewhere classified
Online Access:	https://hdl.handle.net/2134/33084
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id	rr-article-9568442
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spelling	rr-article-95684422018-04-04T00:00:00Z VOLCO: A predictive model for 3D printed microarchitecture Andy Gleadall (4378279) Ian A. Ashcroft (7125329) Joel Segal (4967329) Mechanical engineering not elsewhere classified 3D printing 3D geometry modelling Finite element analysis Voxel model Tissue engineering scaffolds Mechanical Engineering not elsewhere classified Material extrusion additive manufacturing is widely used for porous scaffolds in which polymer filaments are extruded in the form of log-pile structures. These structures are typically designed with the assumption that filaments have a continuous cylindrical profile. However, as a filament is extruded, it interacts with previously printed filaments (e.g. on lower 3D printed layers) and its geometry varies from the cylindrical form. No models currently exist that can predict this critical variation, which impacts filament geometry, pore size and mechanical properties. Therefore, expensive time-consuming trial-and-error approaches to scaffold design are currently necessary. Multiphysics models for material extrusion are extremely computationally-demanding and not feasible for the size-scales involved in scaffold structures. This paper presents a new computationally-efficient method, called the VOLume COnserving model for 3D printing (VOLCO). The VOLCO model simulates material extrusion during manufacturing and generates a voxelised 3D-geometry-model of the predicted microarchitecture. The extrusion-deposition process is simulated in 3D as a filament that elongates in the direction that the print-head travels. For each simulation step in the model, a set volume of new material is simulated at the end of the filament. When previously 3D printed filaments obstruct the deposition of this new material, it is deposited into the nearest neighbouring voxels according to a minimum distance criterion. This leads to filament spreading and widening. Experimental validation demonstrates the ability of VOLCO to simulate the geometry of 3D printed filaments. In addition, finite element analysis (FEA) simulations utilising 3D-geometry-models generated by VOLCO demonstrate its value and applicability for predicting mechanical properties. The presented method enables structures to be validated and optimised prior to manufacture. Potential future adaptations of the model and integration into 3D printing software are discussed. 2018-04-04T00:00:00Z Text Journal contribution 2134/33084 https://figshare.com/articles/journal_contribution/VOLCO_A_predictive_model_for_3D_printed_microarchitecture/9568442 CC BY 4.0
institution	Loughborough University
collection	Figshare
topic	Mechanical engineering not elsewhere classified 3D printing 3D geometry modelling Finite element analysis Voxel model Tissue engineering scaffolds Mechanical Engineering not elsewhere classified
spellingShingle	Mechanical engineering not elsewhere classified 3D printing 3D geometry modelling Finite element analysis Voxel model Tissue engineering scaffolds Mechanical Engineering not elsewhere classified Andy Gleadall Ian A. Ashcroft Joel Segal VOLCO: A predictive model for 3D printed microarchitecture
description	Material extrusion additive manufacturing is widely used for porous scaffolds in which polymer filaments are extruded in the form of log-pile structures. These structures are typically designed with the assumption that filaments have a continuous cylindrical profile. However, as a filament is extruded, it interacts with previously printed filaments (e.g. on lower 3D printed layers) and its geometry varies from the cylindrical form. No models currently exist that can predict this critical variation, which impacts filament geometry, pore size and mechanical properties. Therefore, expensive time-consuming trial-and-error approaches to scaffold design are currently necessary. Multiphysics models for material extrusion are extremely computationally-demanding and not feasible for the size-scales involved in scaffold structures. This paper presents a new computationally-efficient method, called the VOLume COnserving model for 3D printing (VOLCO). The VOLCO model simulates material extrusion during manufacturing and generates a voxelised 3D-geometry-model of the predicted microarchitecture. The extrusion-deposition process is simulated in 3D as a filament that elongates in the direction that the print-head travels. For each simulation step in the model, a set volume of new material is simulated at the end of the filament. When previously 3D printed filaments obstruct the deposition of this new material, it is deposited into the nearest neighbouring voxels according to a minimum distance criterion. This leads to filament spreading and widening. Experimental validation demonstrates the ability of VOLCO to simulate the geometry of 3D printed filaments. In addition, finite element analysis (FEA) simulations utilising 3D-geometry-models generated by VOLCO demonstrate its value and applicability for predicting mechanical properties. The presented method enables structures to be validated and optimised prior to manufacture. Potential future adaptations of the model and integration into 3D printing software are discussed.
format	Default Article
author	Andy Gleadall Ian A. Ashcroft Joel Segal
author_facet	Andy Gleadall Ian A. Ashcroft Joel Segal
author_sort	Andy Gleadall (4378279)
title	VOLCO: A predictive model for 3D printed microarchitecture
title_short	VOLCO: A predictive model for 3D printed microarchitecture
title_full	VOLCO: A predictive model for 3D printed microarchitecture
title_fullStr	VOLCO: A predictive model for 3D printed microarchitecture
title_full_unstemmed	VOLCO: A predictive model for 3D printed microarchitecture
title_sort	volco: a predictive model for 3d printed microarchitecture
publishDate	2018
url	https://hdl.handle.net/2134/33084
_version_	1797553901991362560

VOLCO: A predictive model for 3D printed microarchitecture

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