An orientation-based homogenization approach for predicting process-induced deformations in extrusion-based additive manufacturing

This work presents a homogenization approach for considering process-specific mesostructures typical for material extrusion in finite element simulations to predict process-induced deformation. The approach is based on adapted orientation tensors and orientation averaging, accounting for the characteristic mesostructure and directionality of the material extrusion process. The method addresses the challenge of modeling mesostructural effects across entire components with computationally feasible element sizes. It is implemented in Python and Abaqus, and validated experimentally with PLA, showing good agreement between measured and predicted process-induced deformation. Comparative simulations with an isotropic stiffness formulation demonstrate the significant impact of considering mesostructural anisotropy, highlighting improvements over conventional approaches. Numerical studies further show the evolution of effective material orientation during printing, underscoring the advantages of the anisotropic approach. This method enables efficient, physically consistent integration of material extrusion mesostructures into process-induced deformation prediction, supporting enhanced process design and reliability in material extrusion manufactured components.