Thermal Analysis of Filament Extrusion

Shape Memory Polymer Cooling Profile Program

University of Alberta — Master’s Research Support

Problem

Researchers in the Multi-Functional Compsite Materials Lab were extruding a shape memory polymer filament from polymer pelets for 3D printing but needed a way to predict how the filament would cool during extrusion. Cooling rate affects filament quality, extrusion stability, and whether liquid or air cooling is required.

Approach

• Developed a MatLab program to model the cooling profile of extruded filament.

• Incorporated both differential equations and the lumped system approximation (Biot < 0.1) to account for different heat transfer conditions.

• Added functionality to estimate the length of filament extruded during cooling, improving process predictions.

• Provided researchers with a tool to quickly compare air vs. liquid cooling requirements for different filament diameters and materials.

Result

Delivered a flexible simulation tool that improved the reliability and quality of shape memory polymer filaments for 3D printing. The program helped guide experimental design, reduced trial-and-error, and supported ongoing research into advanced printable materials.