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This study proposes an advanced progressive numerical modeling approach to investigate heat transfer phenomena occurring in the 3D printing of continuous carbon fiber-reinforced co-polyamide (Copa) composites. The material extrusion process is simulated using element activation techniques and active cooling methods, while thermal boundary conditions are updated during the printing process. Differential Scanning Calorimetry (DSC) tests are conducted on composite and neat polymer samples to include the crystallization behavior, where the Hoffman–Lauritzen model is employed for crystallization modeling based on the input data from DSC tests. It is demonstrated that the proposed modeling approach, coupled with the Hoffman–Lauritzen crystallization model, accurately predicts the thermal history of the composite extrudate post-deposition. In the case of a neat polymer, the results of the developed FEM model align well with existing literature. Experimental in-situ temperature measurements utilizing thermal vision agree very well with the predictions of the heat transfer model developed for 3D printing of continuous fiber-reinforced Copa composites, demonstrating the model's capability to predict temperature profiles during printing.
Parviz et al. (Tue,) studied this question.