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Accurate simulation of the printing process is essential for improving printquality, reducing waste, and optimizing the printing parameters ofextrusion-based additive manufacturing. Traditional additive manufacturingsimulations are very compute-intensive and are not scalable to simulate evenmoderately-sized geometries. In this paper, we propose a general framework forcreating a digital twin of the dynamic printing process by performing physicssimulations with the intermediate print geometries. Our framework takes ageneral extrusion-based additive manufacturing G-code, generates ananalysis-suitable voxelized geometry representation from the print schedule,and performs physics-based (transient thermal and phase change) simulations ofthe printing process. Our approach leverages parallel adaptive octree meshesfor both voxelated geometry representation as well as for fast simulations toaddress real-time predictions. We demonstrate the effectiveness of our methodby simulating the printing of complex geometries at high voxel resolutions withboth sparse and dense infills. Our results show that this approach scales tohigh voxel resolutions and can predict the transient heat distribution as theprint progresses. This work lays the computational and algorithmic foundationsfor building real-time digital twins and performing rapid virtual printsequence exploration to improve print quality and further reduce materialwaste.

Geometric Modeling and Physics Simulation Framework for Building a Digital Twin of Extrusion-based Additive Manufacturing