Page 1 of 27 - Cover Page Submission ID trn:oid:::1:3068273855

Amarjot Kaur
Research Paper_R2.docx
fgtf

B1 VISUAL

Khoa_QTKD

Document Details

Submission ID

trn:oid:::1:3068273855 25 Pages

Submission Date 6,173 Words

Nov 6, 2024, 1:31 AM GMT+7

37,269 Characters

Download Date

Nov 6, 2024, 1:43 AM GMT+7

File Name

Research_Paper_R2.docx

File Size

1.4 MB

Page 1 of 27 - Cover Page Submission ID trn:oid:::1:3068273855

 Page 2 of 27 - AI Writing Overview Submission ID trn:oid:::1:3068273855

51% detected as AI Caution: Review required.

The percentage indicates the combined amount of likely AI-generated text as It is essential to understand the limitations of AI detection before making decisions
well as likely AI-generated text that was also likely AI-paraphrased. about a student’s work. We encourage you to learn more about Turnitin’s AI detection
capabilities before using the tool.

Detection Groups
1 AI-generated only 51%
Likely AI-generated text from a large-language model.

2 AI-generated text that was AI-paraphrased 0%

Likely AI-generated text that was likely revised using an AI-paraphrase tool
or word spinner.

Disclaimer
Our AI writing assessment is designed to help educators identify text that might be prepared by a generative AI tool. Our AI writing assessment may not always be accurate (it may misidentify
writing that is likely AI generated as AI generated and AI paraphrased or likely AI generated and AI paraphrased writing as only AI generated) so it should not be used as the sole basis for
adverse actions against a student. It takes further scrutiny and human judgment in conjunction with an organization's application of its specific academic policies to determine whether any
academic misconduct has occurred.

Frequently Asked Questions

How should I interpret Turnitin's AI writing percentage and false positives?

The percentage shown in the AI writing report is the amount of qualifying text within the submission that Turnitin’s AI writing
detection model determines was either likely AI-generated text from a large-language model or likely AI-generated text that was
likely revised using an AI-paraphrase tool or word spinner.

False positives (incorrectly flagging human-written text as AI-generated) are a possibility in AI models.

AI detection scores under 20%, which we do not surface in new reports, have a higher likelihood of false positives. To reduce the
likelihood of misinterpretation, no score or highlights are attributed and are indicated with an asterisk in the report (*%).

The AI writing percentage should not be the sole basis to determine whether misconduct has occurred. The reviewer/instructor
should use the percentage as a means to start a formative conversation with their student and/or use it to examine the submitted
assignment in accordance with their school's policies.

What does 'qualifying text' mean?

Our model only processes qualifying text in the form of long-form writing. Long-form writing means individual sentences contained in paragraphs that make up a
longer piece of written work, such as an essay, a dissertation, or an article, etc. Qualifying text that has been determined to be likely AI-generated will be
highlighted in cyan in the submission, and likely AI-generated and then likely AI-paraphrased will be highlighted purple.

Non-qualifying text, such as bullet points, annotated bibliographies, etc., will not be processed and can create disparity between the submission highlights and the
percentage shown.

Page 2 of 27 - AI Writing Overview Submission ID trn:oid:::1:3068273855

 Page 3 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

Parametric Analysis, Prediction and Improvement of warpage in 3D printed parts

fabricated using material extrusion process

Muhammad Sufyan a, Muhammad Rizwan ul Haq a *, Aamer Nazir b, c

, Muhammad Salman
Khan a
a
Department of Design and Manufacturing Engineering, School of Mechanical and Manufacturing Engineering
(SMME), National University of Sciences and Technology (NUST), H-12, Islamabad, Pakistan

b
Department of Mechanical Engineering, King Fahd University of Petroleum & Minerals, Dhahran, 31261, Saudi
Arabia

c
Interdisciplinary Research Center on Advanced Materials, King Fahd University of Petroleum & Minerals,
Dhahran,31261, Saudi Arabia

* Corresponding Author: [Link]@[Link], aamer

Abstract
Additive Manufacturing (AM) has revolutionized the production process by enabling the creation
of complex geometries with reduced material waste. Additive Manufacturing (AM) proves to be
highly valuable in a range of sectors, encompassing aerospace, automotive, healthcare, and
consumer goods, which is linked to its talent for crafting personalized elements with notable
precision. Fused Deposition Modeling (FDM) is a prominent technique in the realm of additive
manufacturing, attributed to its economic practicality, user-friendly execution, and material
flexibility. Nevertheless, like any established manufacturing process, Fused Deposition Modeling
(FDM) is prone to defects that can undermine the integrity of the resultant product. A significant
imperfection commonly identified in FDM is warpage, which is defined by the undesirable
distortion of components during the fabrication process. Warpage predominantly occurs due to
uneven thermal stresses that manifest during the cooling phase, resulting in dimensional variations.
This imperfection negatively affects the mechanical attributes of the component and reduces its
operational precision, particularly in contexts where accuracy is critical. The current study
endeavors to predict and ameliorate warpage in FDM-printed components through the application
of process optimization strategies. The established predictive model achieved a remarkable degree
of accuracy, demonstrating less than 10% deviation, as validated through thorough experimental
assessments. Simulation results indicate that a Filled Centered Cross (FCC) raster configuration
alleviates warpage by 40% when compared to a grid raster configuration.

Page 3 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 4 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

Key Words: Additive Manufacturing, FDM, warpage, optimization, compensation, FEA

1. Introduction Commented [o1]: The paper still needs more work as you
just increased the sizes of pictures too much to increase the
number of pages.
Additive manufacturing (AM) constitutes a manufacturing methodology that serves as a critical Every section is written too short, add some more discussion
in it. The caption for table and figures have been provided so
cornerstone of Industry 4.0 [1]. The incorporation of additive manufacturing (AM) is witnessing a please modify those along with font size inside the table.
The figures need to be improved as prescribed and by setting
notable escalation across several sectors, including but not confined to manufacturing, aerospace, their sizes.
Results and discussion along with experimental testing and
automotive, and biomedical domains. In light of the escalating application of plastics and polymer validation needs more details.
22 references are too less as make these up to 35.
composites across a multitude of sectors, polymers have become one of the predominant materials Boundary condition and relation of warpage with simulation
results need more logics and details.
utilized within the field of 3D printing [2]. As Fused Deposition Modeling (FDM) progresses,
semi-crystalline polymers are receiving increased scrutiny due to their remarkable mechanical
characteristics, particularly under elevated thermal conditions, in addition to their durability
against both chemical interactions and abrasion. In a comparative analysis with amorphous
polymers, it becomes apparent that semi-crystalline polymers exhibit a pronounced proclivity for
thermal contraction and warping. This phenomenon can be ascribed to the microstructural changes
that transpire during the crystallization process, whereby polymer chains attain a certain level of
organization. As a result, the endeavor of printing semi-crystalline polymers via FDM introduces
substantial challenges and is profoundly affected by the current printing parameters [3].

FDM has revealed significant potential for the production of components featuring complex
geometries, user-centric accessibility, and economic feasibility. Fundamentally, FDM functions as
an extrusion system that employs a movable nozzle, which sequentially deposits molten material
onto the fabrication platform [4]. This technique is particularly proficient in generating
components characterized by intricate designs and meticulous detailing. However, the presence of
residual stresses that accumulate throughout the fabrication process may result in warpage and a
reduction in mechanical properties. [5]. Given that these thermal residual stresses are susceptible
to the impacts of temperature variations, fluctuations in printing parameters can significantly
influence both the quality and the dimensional accuracy of the manufactured parts.[6]

During the FDM process, residual stresses in semi-crystalline polymers develop due to several
influencing elements. During the cooling phase, the polymer material experiences uneven thermal

Page 4 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 5 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

contraction, with the exterior cooling at a significantly faster rate than the interior. [7] This thermal
gradient induces compressive stress on the outer surface, while tensile stress develops within the
core, resulting in anisotropic shrinkage, internal residual stress accumulation, and deformation.
Additionally, the limited thermal conductivity of polymers leads to non-uniform heat distribution
throughout the layers, exacerbating uneven cooling and elevating the potential for residual stresses
and deformation of the final product. [8] A primary factor contributing to residual stress is
crystallization, wherein reduced cooling rates yield higher crystallinity, consequently leading to
an increase in residual stress and warpage. [9].

Recently, there has been an increasing focus on minimizing shrinkage and warpage in printed
semi-crystalline polymers by adjusting processing conditions and material properties through
simulations and experiments. [10] Studies have shown that residual stresses and warpage are
significantly affected by factors such as crystallization degree, thermo-mechanical properties,
viscoelasticity, and volumetric shrinkage. Parameters such as the temperature of the print bed,
thickness of the layers, and ambient temperature are pivotal in ascertaining both the final quality
and the distortion characteristics of the printed component. Investigations conducted by Zhang
and Chou have elucidated that factors including nozzle velocity and layer thickness exert a direct
impact on part distortion, with analogous conclusions being established through subsequent
analyses concerning the cooling mechanisms of 3D-printed components. [11]

Warpage represents a significant challenge within the realm of additive manufacturing,

especially in the context of the material extrusion technique, where it markedly influences the
dimensional precision and overall quality of the produced components. The phenomenon of
warpage in 3D printed artifacts emerges from non-uniform thermal stresses experienced during
the fabrication process, culminating in undesirable deformations and distortions [12]. Such
discrepancies not only undermine the aesthetic and functional integrity of the components but
also lead to material wastage and heightened production expenditures [13]. As the demand for
high-fidelity, dimensionally stable 3D printed components escalates, the imperative to address
the warpage challenge has become increasingly critical [14].

This study endeavors to tackle the pressing issue of warpage in 3D printed components by
devising a comprehensive predictive model and recommending efficacious strategies for its
alleviation [15]. Through the amalgamation of finite element analysis (FEA) and empirical data,
we systematically delineate the primary determinants contributing to warpage, encompassing
material characteristics, printing parameters, and environmental factors. Our predictive model
undergoes rigorous validation via a series of experimental trials, thereby affirming its robustness
and precision [16]. Moreover, a collection of optimized printing protocols is introduced
alongside innovative design modifications that substantially mitigate warpage [17]. These
solutions are not only pragmatic but also scalable, providing tangible advantages to the 3D
printing sector [18]. By augmenting the dimensional precision and mechanical performance of
MEP-fabricated components, this research advances the overarching objective of rendering 3D
printing a more dependable and economically viable manufacturing alternative [19].

Page 5 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 6 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

Material and Methods

Poly Lactic Acid (PLA) was opted as the key material due to its extensive use in Fused Deposition
Modelling (FDM) and its favorable properties. [14] PLA filaments with a diameter of 1.75 mm
were utilized to fabricate the sample components. This material was chosen for its capacity to yield
high-fidelity prints with complex geometries and its extensively documented performance under
diverse thermal and mechanical conditions [15]. By concentrating on PLA, we aimed to delineate
a comprehensive understanding of the determinants influencing warpage in frequently utilized 3D
printing materials. [16].

Table 1. Presents the material properties of PLA (Poly lactic Acid)

Properties Values
Density 1.24 g/cm3
Tensile strength 60 MPa
Flexural strength 108 MPa
Elongation 9%
Young's Modulus 3100 MPa
Shore Hardness 85 Sh D
Melting Temperature 145-160 ºC
Glass transition temperature 56-64 ºC

A plethora of variables can influence warpage in the Material Extrusion Process, including
material properties, layer thickness, print speed, part design, and cooling rates. This research
specifically investigates three critical parameters: raster pattern, bed temperature, and infill
density, as these factors exert a considerable effect on warpage. The parameters incorporated in
this study are raster pattern, bed temperature, and infill density, each selected for their significant
impact on the warpage behavior of components produced via the Material Extrusion Process. The
raster pattern (BCC, FCC, and Grid) was chosen due to its influence on the internal structure of
the printed component, which directly affects thermal distribution, mechanical properties, and
susceptibility to warping. Distinct patterns influence the manner in which thermal energy is
dissipated during the printing procedure, potentially resulting in inconsistencies in warpage. The
bed temperature was included as it regulates the cooling rate of the printed material. An elevated

Page 6 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 7 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

or reduced bed temperature can create uneven thermal gradients, which are a primary contributor
to warpage. This study evaluates distinct temperature ranges of 40°C, 60°C, and 80°C to determine
the ideal circumstances for alleviating thermal stress and minimizing material distortion. Finally,
infill density (10%, 50%, and 90%) was chosen due to its significant influence on the overall
structural integrity and support of the component. Lower infill densities are typically linked to
reduced resistance to warpage owing to diminished internal support, whereas higher densities may
elicit alternative stress distributions within the component. Analyzing these three parameters
provides a thorough understanding of how process settings can be refined to reduce warpage and
improve the quality of 3D printed components. The internal structures of FCC and BCC raster
patterns are illustrated in Figure 1

Figure 1. Illustrates micro raster patterns of (a) Body-Centered Cubic (BCC) and (b) Face-Centered Cubic (FCC)

2.1 Design of Experiment DOE

This investigation utilized an experimental setup based on the Taguchi method, celebrated for its
reliability in optimizing parameters that enhance both quality and overall performance. The
Taguchi method is distinguished by a methodical and resource-efficient strategy to experimental
design, thereby facilitating the analysis of the impacts of multiple variables and their interrelations
on the resultant output. An L9 orthogonal array was utilized to organize the experiments, thus
guaranteeing a comprehensive and balanced evaluation of the parameter space while concurrently
minimizing the number of trials executed.

Page 7 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 8 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

Table 2. Illustrates the combination of all possible options for process parameters in the experimental setup

Raster Infill Bed Temperature Commented [o2]: Units of each??

Sample
Pattern Density (%) (ºC)
1 FCC 10 40
2 FCC 10 60
3 FCC 10 80
4 FCC 50 40
5 FCC 50 60
6 FCC 50 80
7 FCC 90 40
8 FCC 90 60
9 FCC 90 80
10 BCC 10 40
11 BCC 10 60
12 BCC 10 80
13 BCC 50 40
14 BCC 50 60
15 BCC 50 80
16 BCC 90 40
17 BCC 90 60
18 BCC 90 80
19 Grid 10 40
20 Grid 10 60
21 Grid 10 80
22 Grid 50 40
23 Grid 50 60
24 Grid 50 80
25 Grid 90 40
26 Grid 90 60
27 Grid 90 80

This methodological paradigm facilitated the precise identification of optimal settings, alongside
the evaluation of the influence of each parameter on warpage in three-dimensional printed
components. By employing the Taguchi method, this investigation aimed to achieve a high level
of accuracy and dependability in determining the optimal amalgamation of parameters essential

Page 8 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 9 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

for mitigating warpage, thereby enhancing the overall dimensional fidelity and mechanical
characteristics of the printed components.

2.2 Preparation of Samples

The samples were constructed with dimensions of 50 x 50 x 3 mm to effectively evaluate warpage
behavior within the analytical framework. These designated dimensions provide a sufficient
surface area and slender profile to exhibit the typical thermal gradients and internal stresses that
contribute to warpage, while concurrently circumventing the complexities associated with larger
geometrical configurations. The chosen size further promotes efficient material utilization and
computational modeling, thus facilitating accelerated experimental and simulation processes. The Commented [o3]: Improve this figure by considering the
following as example
subsequent figure delineates the configuration for the preparation of the samples.

Figure 2. Represents the 3D printer's setup, including the build platform, print head, and material feed system.

The assessment of warpage in the printed component is executed through an intricately designed
experimental setup intended to quantify the magnitude of warpage. This configuration typically
incorporates a coordinate measuring machine (CMM) apparatus for evaluating the dimensional
fidelity of the component. The component is situated on a flat reference surface, with
measurements obtained at various locations across its surface to quantify deviations from the
intended design parameters. Furthermore, thermal imaging cameras or infrared detectors may be
employed to observe temperature fluctuations during the cooling phase, which contribute to

Page 9 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 10 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

distortion. The data gathered is subsequently analyzed to establish relationships between distortion
behavior and the process parameters implemented during production, thereby offering significant
insights for the alleviation of deformation in future iterations.

Commented [o4]: Improve the figure by considering the

following as example

Figure 3. Depicts the apparatus used to measure warpage in experimental samples

2.3 Analysis of Signal-to-Noise Ratios and Mean Values for Process

Optimization
Building upon the insights garnered from the Signal-to-Noise (SN) ratio analysis, the optimization
of process parameters is imperative for the attainment of high-performance outcomes characterized
by minimal variability. The SN ratio functions as a significant metric for assessing process
robustness, facilitating the identification of optimal settings that enhance performance while
concurrently mitigating noise or external disturbances. Through the examination of critical factors
such as raster pattern, bed temperature, and infill density, the investigation seeks to refine the
material extrusion process to achieve superior part quality. This methodology not only augments
dimensional accuracy but also guarantees consistent mechanical properties, culminating in the
Commented [o5]: Figure captions need to be under the
production of more reliable and durable final products. figure with font size 10 New Times Roman while for tables
it needs to be above table with same font size.
Table 3. Display the response table for Signal to Noise Ratio (SNR) values for various experimental conditions

Page 10 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 11 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

Level Raster Infill Bed

Pattern Density Temperature
(%) (ºC)

1 48.57 50.47 49.88

2 48.13 50.49 49.4
3 53 48.75 50.43
Delta 4.87 1.74 1.03
Rank 1 2 3

Based on the Signal-to-Noise (SN) ratio analysis carried out in Minitab (Building upon the
insights garnered from the Signal-to-Noise (SN) ratio analysis, the optimization of process
parameters is imperative for the attainment of high-performance outcomes characterized by
minimal variability. The SN ratio functions as a significant metric for assessing process robustness,
facilitating the identification of optimal settings that enhance performance while concurrently
mitigating noise or external disturbances. Through the examination of critical factors such as raster
pattern, bed temperature, and infill density, the investigation seeks to refine the material extrusion
process to achieve superior part quality. This methodology not only augments dimensional
accuracy but also guarantees consistent mechanical properties, culminating in the production of
more reliable and durable final products.

Table 3), it is observed that the Raster pattern exhibits the highest SN ratio at level 3, indicating that

this setting provides the most robust performance with minimal variation. Following this, the bed
temperature shows a significant impact at level 3, contributing positively to the process stability.
Interestingly, the infill density demonstrates its highest SN ratio at level 2, suggesting that this
intermediate level offers the best balance between performance and consistency in the output.

Table 4. Display the mean values of the response variable across different experimental conditions Commented [o6]: Editing mistakes as describe in above
figure’s comment

Level Raster Infill Bed

Pattern Density Temperature
(%) (ºC)

1 288.9 377.8 344.4

Page 11 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 12 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

2 266.7 350 311.1

3 461.1 288.9 361.1
Delta 194.4 288.9 50
Rank 1 2 3 Commented [o7]: Units? Inside the table, the font needs
to be 11 Times roman.

Analyzing the response table for means in Minitab, it is evident that the Raster pattern achieves
the highest mean value at level 3, suggesting that this setting produces the most favorable average
outcome. Similarly, the bed temperature also shows the highest mean at level 3, indicating optimal
performance at this level. Meanwhile, the infill density reaches its peak mean value at level 2,
highlighting that this intermediate setting provides the best average result for the process.

2.4 Normal and Maximum Likely hood Estimation

Analysis of probability plot was performed for all the samples as seen in Figure 4 . The probability
graph of the output reveals the distribution and variability of the process results.

Figure 4. Normal probability plot illustrates the distribution of data points and assesses whether the data follows a
normal distribution. Commented [o8]: Improve the caption and figure

Page 12 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 13 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

The graph illustrates how closely the output data aligns with the expected distribution, providing
insights into the process's consistency and predictability. A well-aligned probability graph suggests
that the process is stable, with the majority of the output falling within the desired range. Any
deviations or shifts in the graph can indicate potential areas for improvement or the presence of
factors influencing the process unpredictably. This analysis helps in identifying outliers and
understanding the overall reliability of the process outcomes.

2. Results and Discussions

In this study, a specific element is selected from the first layer to observe the heating of layers. In
the FDM printing, the new deposited hot layer can start the re-crystallization of the bottom layer.
Layer depending upon the crystallization temperature of the material. It results in the melting of
the solidified polymer crystals. During this process, solidified polymer layers are melted again.

Page 13 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 14 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

Figure 5. Main effect plots for means of SN Ratios are plotted to see effect of factor response changes as the levels
of each factor change

It can be seen from Figure 5 that Raster pattern is showing an upward trend for Grid pattern. It
indicates that the process is becoming more robust. This means that as the factor level increases or
decreases, the process's ability to produce consistent, high-quality results improves. A downward
trend in the Infill density suggests increasing sensitivity to noise as the factor level changes. This
implies that the process is becoming less reliable, with greater variability and less consistent
outcomes. It is showing an optimized, high quality result with FCC raster pattern as noise is less
at FCC pattern.

After the deposition of few layers, bottom layer is only heated slightly since the heat is below
crystallization temperature. This results in cold crystallization. The work mainly focuses on the
analyzation of data from the specific element in first layer.

3.1 Printed Parts:

Commented [o9]: Improve the figure in which by you can

Bed Grid Pattern BCC Pattern FCC Pattern show warpage either in the form of straight line or some
other way.. think about and improve the figure???
Temp 10% Infill 10% Infill 10% Infill

40 ºC

60 ºC

80 ºC

Grid Pattern BCC Pattern FCC Pattern

50% Infill 50% Infill 50% Infill

40 ºC

60 ºC

80 ºC

Grid Pattern BCC Pattern FCC Pattern

90% Infill 90% Infill 90% Infill

Page 14 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 15 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

40 ºC

60 ºC

80 ºC

Figure 6. Samples printed using various process parameters as specified by the Design of Experiments (DOE) to
evaluate the levels of warpage in a controlled fashion

Warpage in all the samples printed was measured as shown in Figure 6. Samples printed using various
process parameters as specified by the Design of Experiments (DOE) to evaluate the levels of warpage in a controlled
fashion Figure 6. Specifically with a 90% infill density, FCC raster Pattern, 80ºC bed temperature,

0.1 mm layer height, the part is showing the least warpage. At 90% infill, entrapped heat is easily
transmitted to sides leading to less warpage. Also, 80C bed temperature is best optimum as
temperature gradient is less with molten PLA. This leads to a better temperature distribution. FCC
Pattern has atoms in each faces and atomic packing factor of FCC is 0.74, having better tendency
of temperature distribution. Whereas BCC has an atomic packing factor of 0.68, it shows a
medium response to warpage. The optimized heat distribution, reduced thermal gradients, and
improved inter-layer bonding collectively contribute to the reduced warpage observed in the
samples. These findings highlight the importance of selecting appropriate printing parameters to
achieve high-quality parts with minimal deformation.

Grid raster pattern is showing the worst response. Due to its geometric configuration, it effectively
captures the majority of thermal energy. As the temperature of the build platform rises, the thermal
gradient diminishes, resulting in more homogeneous cooling of the fabricated component. The
geometric configuration of the grid raster pattern engenders numerous intersecting lines that
confine heat within the framework, thereby obstructing its uniform dissipation throughout the
component. This entrapment of thermal energy induces localized regions of elevated temperature,
culminating in inconsistent cooling and heightened thermal gradients. Such thermal gradients
represent a significant contributor to the emergence of internal stresses within the component,
which ultimately leads to considerable deformation during the cooling process. As the temperature
of the build platform escalates, a reduction in the thermal gradient between the platform and the
liquefied PLA occurs. This diminished gradient facilitates the attainment of more uniform cooling,

Page 15 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 16 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

which theoretically could mitigate warpage. Nonetheless, in the context of the grid pattern, the
intrinsic geometry continues to facilitate non-uniform heat distribution, notwithstanding the
elevated temperature of the build platform. The thermal energy remains confined within the grid
configuration, resulting in disparate cooling rates across the component and exacerbating the
warpage phenomenon.

Additionally, the dense intersections within the grid pattern contribute to the formation of weak
points where stresses are more likely to concentrate. These stress concentration points further
amplify the likelihood of warpage as the part cools. The grid pattern’s inability to effectively
distribute heat and alleviate these stress points makes it the least favorable option among the tested
patterns in terms of warpage control.

Commented [o10]: Study the graph and compare with

literature that which is dominant factor in each graph and
what’s the effect of others?
Commented [o11]: Same comment as above figure.

Figure 7. Presents separate 3D plots of the measured warpage for BCC (Body-Centered Cubic).
Each plot visualizes the warpage as a function of process parameters, such as infill density and bed temperature.

Page 16 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 17 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

The analysis of the BCC plot reveals that the majority of the surface is relatively flat, indicating
that changes in infill density and bed temperature have a minimal effect on warpage across much
of the parameter space. This suggests that within certain ranges, these factors do not significantly
contribute to part distortion under the BCC raster pattern. However, a notable upward steep is
observed at the corner where both infill density and bed temperature are at their highest values,
pointing to a sharp increase in warpage. This steep rise highlights that the combination of high
infill density and elevated bed temperature plays a dominant role in increasing warpage. The
increased infill density, while providing greater internal support, also leads to higher internal
stresses, and when coupled with elevated bed temperature, it results in altered cooling dynamics
that exacerbate deformation. This observation aligns with findings in the literature, where higher
infill density and bed temperature are linked to greater shrinkage and warpage, particularly when
not carefully controlled. Thus, optimizing both parameters is crucial to minimizing warpage in
FDM processes.

Page 17 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 18 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

Figure 8. Presents separate 3D plots of the measured warpage for FCC (Face-Centered Cubic). Each plot visualizes
the warpage as a function of process parameters, such as infill density and bed temperature.

The examination of the FCC plot elucidates a distinct ascending gradient as infill density escalates,
signifying that infill density exerts a considerable influence on warpage within this domain. In
contrast to the BCC plot, the FCC plot exhibits a non-linear configuration and reveals prominent
peaks, underscoring regions of maximum warpage that correlate with elevated infill density. This
observation implies that as the internal architecture of the component attains greater density, the
internal stresses intensify, resulting in increased deformation. The peaks depicted in the plot
represent critical junctures where warpage reaches its zenith, accentuating the preeminent role of
infill density in modulating component distortion under the FCC raster arrangement.

Figure 9. Presents separate 3D plots of the measured warpage for Grid. Each plot visualizes the warpage as a
function of process parameters, such as infill density and bed temperature.

Page 18 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 19 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

The investigation of the Grid plot uncovers a general ascending trajectory, indicating that both
infill density and bed temperature significantly affect warpage throughout the parameter spectrum.
The plot illustrates a notably steep incline at the juncture where both infill density and bed
temperature achieve their maximum values, implying a robust correlation between these variables
and the augmentation of warpage. This upward trend suggests that as infill density escalates, in
conjunction with elevated bed temperature, the propensity for component distortion markedly
increases. The enhanced material density contributes to elevated internal stresses, while increased
bed temperatures facilitate thermal expansion and non-uniform cooling, culminating in more
pronounced warpage. This phenomenon aligns with extant literature, which posits that both infill
density and bed temperature are pivotal determinants of the dimensional stability of components,
particularly when subjected to their maximal extremes. Therefore, controlling these parameters is
essential to minimize warpage in FDM, especially when using a Grid raster pattern.

Furthermore, the thermal gradients of the samples were validated using the IR camera. It can be
seen that thermal predictions and IR camera results match in accordance to each other. Figure 10 is Commented [o12]: Proper cross reference the figures by
using list of figures.
showing the thermal images of the reference sample at different time scales. It can be seen that
Sample a starts to cool down from the corners and outside while it inner side remain at a higher
temperature. The outer surface cools at a much faster rate than inner side. This lead to distortion
in the geometry of the part. Moreover, the corners of the FDM printed parts are more prone to
warpage.

Commented [o13]: Group these figures and write (a)

(b)…. And describe in text.

Page 19 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 20 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

t = 340 s t= 470 s t=600 s

Figure 10. Thermal image showing temperature distribution after the completion of the printing process

From simulated wafer shown in the figure below, it can be clearly seen that corners of the part are Commented [o14]: ???

more prone to warpage. It is due to fact that, heat can be easily dissipated from the corners leading
to decrease in temperature from the corners. The inner matter remain in molten form. This
differentiation in the temperature, leads to distortion in part.

Figure 11. Representing the warpage results of the simulated 3D printed part

3.2 Comparison of warpage in samples

The experimental validation of warpage results by comparing 3D scanned data with simulation
outcomes demonstrates the reliability and precision of the predictive model developed for this
study. The warpage comparison, as shown in the table, reveals a high degree of accuracy, with
simulated values closely matching those obtained from physical samples. This strong correlation

Page 20 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 21 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

between predicted and measured warpage not only confirms the model's capability to anticipate
warpage behavior but also underscores the robustness of the simulation methodology in capturing
complex deformation patterns inherent in material extrusion processes. Commented [o15]: Improve the graph by moving the y
axis legend to the left and start sample numbering from 1,
2,….from left to right
1.4

1.2

0.8
Warpage

0.6

0.4

0.2

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Samples
Measured Warpage (mm) Predicted warpage (mm)

Figure 12. Compares the measured warpage values with the predicted warpage values across different samples

Such accurate predictions are crucial in the context of additive manufacturing, where warpage can
significantly affect dimensional accuracy, surface quality, and structural integrity of fabricated
parts. By validating the predictive model, the study showcases the potential of this simulation-
based approach to serve as a dependable tool for preemptively identifying and mitigating warpage
issues. This could facilitate faster design iterations, reduce the need for extensive experimental
testing, and ultimately minimize production costs and lead times.

Furthermore, the alignment of simulated and experimental data strengthens the model's
applicability for a wide range of conditions and materials within the field of material extrusion.
This approach could play a transformative role in advancing manufacturing precision, enabling
engineers to optimize process parameters, and improve part quality systematically. Consequently,

Page 21 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 22 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

the validated model holds promise as an indispensable asset for both academic research and
industrial practices, contributing to the refinement and control of warpage effects in future additive
manufacturing applications

2.3 Experimental Validation

Table 5 the text presents a comprehensive comparison of warpage across diverse specimens,
emphasizing significant disparities in their performance under varying process parameters. Upon
scrutiny, Specimens 1, 2, and 3 demonstrate the minimal extent of warpage, signifying that
particular elements contribute to enhanced dimensional stability in these instances. Specimen 1,
which incorporates the FCC Pattern, exhibits exceptional heat dissipation properties. This prompt
and more effective dissipation of heat mitigates thermal gradients, consequently reducing residual
stresses and, as a result, warpage. The influence of this pattern is congruent with prior
investigations that propose optimized tool trajectories and layer configurations assist in regulating
deformation.

For Specimen 2, the diminished warpage can be predominantly ascribed to its lower infill density.
The consistent distribution of heat throughout the component, enabled by a less dense internal
architecture, results in a reduction of overall residual stress. This observation aligns with the
conclusions drawn by Zhang and Chou, as well as Zhang et al., who stress that elevated infill
densities can induce increased stress accumulation, ultimately culminating in more pronounced
warpage. The reduced density in Specimen 2 facilitates a more uniform heat transfer, averting the
concentration of stresses that could otherwise warp the component.

Conversely, Specimen 4 exhibits the most pronounced warpage, which can be ascribed to the
application of extreme process parameters. The amalgamation of elevated bed temperature, infill
density, and suboptimal raster patterns engenders substantial internal stresses during the cooling
phase, exacerbating warpage. This outcome underscores the necessity of meticulously balancing
process parameters to avert extreme conditions that may jeopardize the structural integrity of the
fabricated components.

Page 22 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 23 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

This examination not only bolsters the existing literature on warpage mitigation in additive
manufacturing but also furnishes pragmatic insights into optimizing critical process parameters to
attain dimensional precision in Fused Deposition Modeling (FDM).

Table 5. Experimental validation of warpage in FEA model with measured values

Measured Warpage Predicted warpage Deviation

(mm) (mm) (%)
Sample 1 0.75 0.77 2.7
Sample 2 0.6 0.58 3.3
Sample 3 0.8 0.82 2.5
Sample 4 1.25 1.18 5.6
Sample 5 0.95 0.92 3.15

3. Conclusions
This study investigated the impact of various printing parameters, including bed temperature, infill
density and raster pattern, on warpage and residual stresses. Simulation results indicate that a FCC
raster pattern reduces warpage by 40% compared to a grid raster pattern. Additionally, increasing
the bed temperature leads to an additional 21% decrease in warpage. The study found that the semi
crystalline nature of the polymer and the temperature dependence of its thermomechanical
properties significantly influence the residual stress in 3D-printed components. This methodology
provides quantitative predictions of part distortion, revealing the relationship between printing
conditions, crystallization, residual stresses, and warpage in FDM-printed parts.

The warpage results between simulated and 3D-printed samples are presented. The predicted
warpage using FEA for sample 2 is 0.68 mm, compared to the measured warpage of 0.65 mm,
with a deviation of 4.61%. For sample 4, the predicted warpage is 1.18 mm, while the measured

Page 23 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 24 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

warpage is 1.25 mm, resulting in a deviation of 5.62%. This demonstrates the model's accuracy in
predicting part warpage, with a deviation of less than 6%.

The experimentally obtained 3D scanned data from a printed part corroborated the warpage
predictions of the simulated model. These findings provide insights into how polymer properties
and printing parameters influence residual stresses and warpage during FDM of semi-crystalline
polymers, which can be used to minimize shrinkage and warpage in 3D-printed parts. Commented [o16]: In conclusions, cross referencing if
not allowed. Write the discrete results in the form of points.
Last paragraph can be future work by carrying this work.
For prospective endeavors, supplementary investigation can concentrate on optimizing additional
procedural parameters such as nozzle temperature, cooling rates, and extrusion velocity to augment
dimensional stability and mitigate warpage in Fused Deposition Modeling (FDM) components.
Furthermore, examining the impact of diverse material compositions, encompassing composites
or hybrid substances, could furnish novel perspectives on regulating deformation. Sophisticated
simulation methodologies incorporating machine learning algorithms may yield predictive models
for warpage under fluctuating conditions. Empirical analyses on larger and more intricate
geometries would also be advantageous to substantiate current discoveries. Ultimately, the
incorporation of real-time monitoring systems during the printing process could facilitate dynamic
modifications to procedural parameters, thereby minimizing defects in real-time.

References:
1. Wang, T.-M., J.-T. Xi, and Y. Jin, A model research for prototype warp deformation in
the FDM process. The International Journal of Advanced Manufacturing Technology,
2007. 33: p. 1087-1096.
2. Xu, H. and C. Bellehumeur, Thermal residual stress development for semi‐crystalline
polymers in rotational molding. Polymer Engineering & Science, 2008. 48(2): p. 283-
291.
3. Favaloro, A.J., et al., Simulation of polymeric composites additive manufacturing using
Abaqus. Science in the Age of Experience, 2017: p. 103-114.
4. Spoerk, M., et al., Polypropylene filled with glass spheres in extrusion‐based additive
manufacturing: effect of filler size and printing chamber temperature. Macromolecular
materials and engineering, 2018. 303(7): p. 1800179.
5. Brenken, B., et al., Development and validation of extrusion deposition additive
manufacturing process simulations. Additive manufacturing, 2019. 25: p. 218-226.
6. Balani, S.B., Additive manufacturing of the high-performance thermoplastic:
experimental study and numerical simulation of the Fused Filament Fabrication. 2019,
Institut National Polytechnique de Toulouse-INPT.

Page 24 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 25 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

7. Zhang, Y. and K. Chou, A parametric study of part distortions in fused deposition

modelling using three-dimensional finite element analysis. Proceedings of the Institution
of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2008. 222(8): p.
959-968.
8. Spina, R., et al., Analysis of polymer crystallization and residual stresses in injection
molded parts. International journal of precision engineering and manufacturing, 2014. 15:
p. 89-96.
9. Levy, A., Robust numerical resolution of Nakamura crystallization kinetics. International
Journal of Theoretical and Applied Mathematics, 2017(4): p. 143.
10. Le Goff, R., et al., Study and modeling of heat transfer during the solidification of semi-
crystalline polymers. International Journal of Heat and Mass Transfer, 2005. 48(25-26):
p. 5417-5430.
11. Xu, Q., et al., A new nonlinear viscoelastic model and mathematical solution of solids for
improving prediction accuracy. Scientific reports, 2020. 10(1): p. 2202.
12. Popescu, D., et al., FDM process parameters influence over the mechanical properties of
polymer specimens: A review. Polymer Testing, 2018. 69: p. 157-166.
13. El Moumen, A., M. Tarfaoui, and K. Lafdi, Modelling of the temperature and residual
stress fields during 3D printing of polymer composites. The International Journal of
Advanced Manufacturing Technology, 2019. 104: p. 1661-1676.
14. Xia, H., et al., Fully resolved numerical simulations of fused deposition modeling. Part I:
fluid flow. Rapid Prototyping Journal, 2018. 24(2): p. 463-476.
15. Levy, A., S. Le Corre, and V. Sobotka. Heat transfer and crystallization kinetics in
thermoplastic composite processing. A coupled modelling framework. in AIP Conference
Proceedings. 2016. AIP Publishing.
16. Dreßler, M., et al., Temperature distribution in powder beds during 3D printing. Rapid
Prototyping Journal, 2010. 16(5): p. 328-336.
17. Xia, H. , L. J. , D. S. , T. G. (2018). Fully Resolved Numerical Simulations of Fused
Deposition Modeling. 463–476.
18. Xia, H., Lu, J., Dabiri, S., Tryggvason, G., 2018, Fully Resolved Numerical Simulations
of Fused Deposition Modeling. Part I: Fluid Flow. Rapid Prototyping Journal, 24:463–
476. [Link]
19. Levy, A., Le Corre, S., Sobotka, V., 2016, Heat Transfer and Crystallization Kinetics in
Thermoplastic Composite Processing. A Coupled Modelling Framework. AIP
Conference Proceedings, 1769. [Link]
20. Dressler, M., Röllig, M., Schmidt, M., Maturilli, A., Helbert, J., 2010, Temperature
Distribution in Powder Beds During 3D Printing. Rapid Prototyping Journal, 16:328–
336. [Link]
21. Edith Wiria, F., Fai Leong, K., Kai Chua, C., 2010, Modeling of Powder Particle Heat
Transfer Process in Selective Laser Sintering for Fabricating Tissue Engineering
Scaffolds. Rapid Prototyping Journal, 16:400–410. [Link]
org/10.1108/13552541011083317.
22. Gartner, T.E., Jayaraman, A., 2019, Modeling and Simulations of Polymers: A Roadmap.
Macromolecules, 52:755–786. [Link]

Page 25 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 26 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

23. Spina, R., et al., Analysis of polymer crystallization and residual stresses in injection
molded parts. International journal of precision engineering and manufacturing, 2014. 15:
p. 89-96.
24. Levy, A., Robust numerical resolution of Nakamura crystallization kinetics. International
Journal of Theoretical and Applied Mathematics, 2017(4): p. 143.
25. Le Goff, R., et al., Study and modeling of heat transfer during the solidification of semi-
crystalline polymers. International Journal of Heat and Mass Transfer, 2005. 48(25-26):
p. 5417-5430.
26. Xu, Q., et al., A new nonlinear viscoelastic model and mathematical solution of solids for
improving prediction accuracy. Scientific reports, 2020. 10(1): p. 2202.
27. Popescu, D., et al., FDM process parameters influence over the mechanical properties of
polymer specimens: A review. Polymer Testing, 2018. 69: p. 157-166.
28. El Moumen, A., M. Tarfaoui, and K. Lafdi, Modelling of the temperature and residual
stress fields during 3D printing of polymer composites. The International Journal of
Advanced Manufacturing Technology, 2019. 104: p. 1661-1676.
29. Xia, H., et al., Fully resolved numerical simulations of fused deposition modeling. Part I:
fluid flow. Rapid Prototyping Journal, 2018. 24(2): p. 463-476.
30. Levy, A., S. Le Corre, and V. Sobotka. Heat transfer and crystallization kinetics in
thermoplastic composite processing. A coupled modelling framework. in AIP Conference
Proceedings. 2016. AIP Publishing.
31. Wang, T.-M., J.-T. Xi, and Y. Jin, A model research for prototype warp deformation in
the FDM process. The International Journal of Advanced Manufacturing Technology,
2007. 33: p. 1087-1096.
32. Xu, H. and C. Bellehumeur, Thermal residual stress development for semi‐crystalline
polymers in rotational molding. Polymer Engineering & Science, 2008. 48(2): p. 283-
291.
33. Favaloro, A.J., et al., Simulation of polymeric composites additive manufacturing using
Abaqus. Science in the Age of Experience, 2017: p. 103-114.
34. Spoerk, M., et al., Polypropylene filled with glass spheres in extrusion‐based additive
manufacturing: effect of filler size and printing chamber temperature. Macromolecular
materials and engineering, 2018. 303(7): p. 1800179.
35. Brenken, B., et al., Development and validation of extrusion deposition additive
manufacturing process simulations. Additive manufacturing, 2019. 25: p. 218-226.
36. Balani, S.B., Additive manufacturing of the high-performance thermoplastic:
experimental study and numerical simulation of the Fused Filament Fabrication. 2019,
Institut National Polytechnique de Toulouse-INPT.
37. Zhang, Y. and K. Chou, A parametric study of part distortions in fused deposition
modelling using three-dimensional finite element analysis. Proceedings of the Institution
of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2008. 222(8): p.
959-968.
38. Spina, R., et al., Analysis of polymer crystallization and residual stresses in injection
molded parts. International journal of precision engineering and manufacturing, 2014. 15:
p. 89-96.
39. Levy, A., Robust numerical resolution of Nakamura crystallization kinetics. International
Journal of Theoretical and Applied Mathematics, 2017(4): p. 143.

Page 26 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

 Page 27 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855

40. Le Goff, R., et al., Study and modeling of heat transfer during the solidification of semi-
crystalline polymers. International Journal of Heat and Mass Transfer, 2005. 48(25-26):
p. 5417-5430.
41. Xu, Q., et al., A new nonlinear viscoelastic model and mathematical solution of solids for
improving prediction accuracy. Scientific reports, 2020. 10(1): p. 2202.
42. Popescu, D., et al., FDM process parameters influence over the mechanical properties of
polymer specimens: A review. Polymer Testing, 2018. 69: p. 157-166.
43. El Moumen, A., M. Tarfaoui, and K. Lafdi, Modelling of the temperature and residual
stress fields during 3D printing of polymer composites. The International Journal of
Advanced Manufacturing Technology, 2019. 104: p. 1661-1676.
44. Xia, H., et al., Fully resolved numerical simulations of fused deposition modeling. Part I:
fluid flow. Rapid Prototyping Journal, 2018. 24(2): p. 463-476.
45. Levy, A., S. Le Corre, and V. Sobotka. Heat transfer and crystallization kinetics in
thermoplastic composite processing. A coupled modelling framework. in AIP Conference
Proceedings. 2016. AIP Publishing.

Page 27 of 27 - AI Writing Submission Submission ID trn:oid:::1:3068273855