Implementation of nozzle motion for material extrusion additive manufacturing in Ansys Fluent

Most computational fluid dynamics (CFD) modelling of material extrusion additive manufacturing (MEX-AM) mainly relies on a moving boundary condition applied to the print bed and not the direct modelling of the motion of the nozzle. This paper presents step-by-step and detailed implementation of the nozzle motion as well as non-isothermal non-Newtonian flow during MEX-AM in Ansys Fluent. For nozzle motion the overset approach is used for the meshing which allows for the nozzle and the rest of the domain to be meshes separately, streamlining meshing and motion. The method is initially used to simulate a single strand, which was validated against experimental and numerical data. It was then applied to demonstrate out-of-plane nozzle motion in two case studies: three-layer printing and printing on a ramp. The model is further developed to simulate a single strand deposition with the well-known Cross–William–Landel–Ferry (Cross-WLF) behaviour for a thermal and shear-dependent material flow.