Multiscale Prediction of Mechanical Behaviour in FDM Polymers via a Process-Driven Mesoscale Model
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In this work, we develop an analytical extrusion model that describes the temperature-dependent flow efficiency of FDM printing. A closed-form relationship is derived to predict the true extruded volume as a function of printing temperature and extrusion multiplier, enabling printer-specific calibration of extrusion behaviour. By comparing the predicted extruded volume with the nominal designed volume, process-induced defects are quantified in terms of porosity. Based on the predicted porosity and prescribed filament dimensions, a mesoscale geometric model is constructed that explicitly relates filament shape to inter-filament air gaps arising from rounded filament cross-sections.
