Enhancing Sustainability in Polymer Additive Manufacturing by Simulations through Computational Fluid Dynamics

This research examines the benefits of utilizing Computational Fluid Dynamics (CFD) simulations to enhance the sustainability of the Arburg Plastic Freeforming (APF) additive manufacturing process, focusing on polycarbonate as the primary material. Simulating polycarbonate’s behavior during extrusion from a heated nozzle into a heat-controlled chamber, this study aims to understand thermal dynamics and material flow to optimize manufacturing. Implementing manufacturing process simulations through CFD presents a significant opportunity to make tailored adjustments to processing parameters, considerably reducing material waste and energy consumption. This capability allows manufacturers to identify efficient workflows and minimize resource use before physical trials, addressing sustainability challenges in the sector. Moreover, the insights derived from these simulations can enhance product quality and durability, reducing the necessity for frequent replacements and supporting overarching sustainability objectives. By illustrating the efficacy of simulation technologies in optimizing the APF process, this research highlights the transformative potential of advanced modeling techniques in driving innovation and promoting sustainable practices in the polymer industry. Ultimately, this study highlights the indispensable role of CFD simulations in facilitating the transition toward more sustainable production methodologies. This work addresses environmental challenges and highlights the importance of strategic simulation practices for achieving sustainability in additive manufacturing and beyond.