Fully Resolved Numerical Simulations of Fused Deposition Modeling

Fully resolved numerical simulations of the deposition of a filament of hot, viscous liquid, and its solidification, are presented. The computations are done using a front tracking/finite volume code designed for direct numerical simulations of multiphase flows, but here we add a volume source that follows a prescribed trajectory to inject the melt. The cooling of the melt is simulated and once it is cool enough the melt is solidified. The result suggest that the deposition is fully captured and that remelting of already solidified material results in a compaction of the deposited filaments.