Modeling and Characterization of Fused Deposition Modeling Tooling for Autoclave Process

Additive manufacturing provides design flexibility, rapid tool development, material reduction, and reduced cost. Fused Deposition Modeling (FDM), an additive manufacturing process for fabrication of 3D parts by computer-controlled extrusion of thermoplastics, allows the produced tools to be utilized in the autoclave process. In the current study, an autoclave process was modeled using finite element analysis for FDM tools under elevated pressure and temperature. Solid and sparse-build tools manufactured with Ultem 9085 were studied. Material and build properties were characterized using compression testing at varying elevated temperatures. A Stratasys Fortus 400mc FDM machines was used to manufacture the Ultem tools, which underwent autoclave cycling with pressure of 100 psi and maximum cure temperatures of 180 °F and 250 °F. Tools were evaluated with dimensional analysis and surface roughness tests before and after the autoclave process. A finite element model examined the thermo-mechanical behavior of the FDM tools affected by an autoclave process.