Effect of internal structure on warpage in a large-scale additive manufacturing process with bio-derived composites

Extrusion-based large-format additive manufacturing (LFAM) often results in unintended deformation and failures due to thermal residual stress between layers. This LFAM involves a hot molten polymer deposited on a previously deposited and cooled layer, generating a temperature mismatch between the layers. The temperature discrepancy causes a thermal contraction mismatch, generating thermal residual stress. Due to the residual stress, printed structures experience warpage and delamination. Therefore, understanding the heat distribution behavior is essential to preventing undesired deformation and failures. The goal of this study is to investigate the effect of infill patterns on heat distribution and deformation in an LFAM system. Wood fiber-reinforced polylactic acid was used as a sustainable and low-cost reinforcement material. A numerical model was developed to predict the temperature and deformation field with thermo-mechanical properties, which were measured by a dynamic mechanical analysis and a thermal expansion test. Simulations were performed on a box geometry with three different infill patterns. The simulation model was verified with temperature data gathered from an infrared camera. The results show good agreement between predicted and measured temperature profiles. The developed simulation model was applied to a roof tray with different infill patterns for a case study. We found that the different thermal mass distributions resulting from the various infill patterns affected the heat distribution and deformation. These findings contribute to a better understanding of the thermal and mechanical behavior of LFAM.