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Despite the growing level of technological advancement that characterizesextrusion-deposition additive manufacturing technology, there remains asignificant knowledge gap in fully understanding the process-structure-propertyrelationship involved in this technology. Modeling the polymer melt flowextrusion-deposition process is important in understanding the development ofthe inherent microstructure within the print beads, particularly themicro-voids formation and growth which significantly affects the resultingmaterial properties and part performance. The current research presents acomputational-based approach for investigating process-induced micro-voids andtheir impact on print properties. We develop a multiscale FEA simulation toolto predict global and local flow-fields during the polymer-melt flow process toinvestigate underlying mechanisms that may promote the micro-void developmentwithin the bead microstructure specifically the occurrence of low-pressureregions at sites of stress concentration such as at the tips of suspendedfibers and at locations with abrupt changes in flow direction like thedie-swell region just after the nozzle exit. The research also investigatespotential factors that may influence the growth and development of thesemicro-voids such as the suspension viscosity and shear-thinning polymer meltrheology, the size and geometry of the reinforcing particles, etc. Furthermore,the research presents a method for quantifying and characterizing micro-voidswithin printed beads and assessing their impact on the effective materialproperties. The direct implication of reduced bead porosity levels is thedevelopment of high-quality functional components for specialized applicationssuch as light weight & high strength integrity composites widely used in avariety of industries particularly the automobile, aerospace, renewable energyand defense industries.

Simulation of Micro-Void Development within Large Scale Additively Manufactured Polymer Composite Deposition Beads