Creation of controlled polymer extrusion prediction methods in fused filament fabrication. An empirical model is presented for the prediction of geometric characteristics of polymer fused filament fabrication manufactured components

This thesis presents a model for the procedures of manufacturing Fused Filament Fabrication (FFF) components by calculating required process parameters \nusing empirical equations. Such an empirical model has been required within the \nFFF field of research for a considerable amount of time and will allow for an expansion in understanding of the fundamental mathematics of FFF. Data acquired \nthrough experimentation has allowed for a data set of geometric characteristics \nto be built up and used to validate the model presented. The research presented \ndraws on previous literature in the fields of additive manufacturing, machine engineering, tool-path programming, polymer science and rheology. Combining these \nresearch fields has allowed for an understanding of the FFF process which has \nbeen presented in its simplest form allowing FFF users of all levels to incorporate \nthe empirical model into their work whilst still allowing for the complexity of the \nprocess. \nInitial literature research showed that Polylactic Acid (PLA) is now in common \nuse within the field of FFF and therefore was selected as the main working material for this project. The FFF technique, which combines extrusion and Computer \nAided Manufacturing (CAM) techniques, has a relatively recent history with little understood about the fundamental mathematics governing the process. This \nproject aims to rectify the apparent gap in understanding and create a basis upon \nwhich to build research for understanding complex FFF techniques and/or processes involving extruding polymer onto surfaces.