Influence of thermal effects and fluid dynamics on part sedimentation in volumetric additive manufacturing

Yi-Fei Wang; Xiao-Xiao Han; Xiao-Long Zhu; Wei Zhu; Feng Chen

doi:10.1007/s40436-026-00599-8

Advances in Manufacturing ›› :1 -22. DOI: 10.1007/s40436-026-00599-8

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Influence of thermal effects and fluid dynamics on part sedimentation in volumetric additive manufacturing

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¹National Engineering Research Centre for High Efficiency Grinding, HNU College of Mechanical and Vehicle Engineering, Hunan University, 410082, Changsha, People’s Republic of China

²State Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle Body, Hunan University, 410082, Changsha, People’s Republic of China

^a fchen@hnu.edu.cn

Yi-Fei Wang

Yi-Fei Wang is a Ph.D. candidate under the supervision of Prof. Xiao-Xiao Han at HNU College of Mechanical and Vehicle Engineering, Hunan University, China. He received M.S. degree from China Academy of Machinery Science and Technology in 2021. His research interests focus on volumetric additive manufacturing technology.

Xiao-Xiao Han

Xiao-Xiao Han is a full professor at HNU College of Mechanical and Vehicle Engineering, Hunan University, China. Her research expertise lies in biomimetic design and 3D printing of cell-laden biodegradable scaffolds. She has published more than 50 peer-reviewed papers in top journals, including Nature Communications, Biomaterials, and Additive Manufacturing, as well as five book chapters. She serves as a guest editor, editorial board member, and reviewer for international journals.

Xiao-Long Zhu

Xiao-Long Zhu is a Ph.D. candidate under the supervision of Prof. Xiao-Xiao Han at HNU College of Mechanical and Vehicle Engineering, Hunan University, China. His research interests include artificial intelligence-assisted biomimetic design of 3D bio-printed tissue scaffolds.

Wei Zhu

Wei Zhu is currently an assistant professor at HNU College of Mechanical and Vehicle Engineering, Hunan University, China. His research interests primarily focus on additive manufacturing of polymers, ceramics, and composites, as well as 3D/4D printing in biomedical engineering. He has authored over 20 peer-reviewed journal articles and contributed to a book chapter, in addition to holding over 10 patents. He serves as an associate editor of Smart Manufacturing and acts as a guest editor for Materials Today and Virtual and Physical Prototyping.

Feng Chen

Feng Chen obtained his Ph.D. from Plymouth University, UK, and is now an associate professor at HNU College of Mechanical and Vehicle Engineering, Hunan University, China. His research focuses mainly on additive manufacturing and 3D bioprinting, with a particular interest in polymer and hydrogel materials. His work has been published in various high-quality journals, such as Nature Communications, Advanced Materials, and Acta Biomaterialia.

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Abstract

Part sedimentation in volumetric additive manufacturing (VAM) technology is a well-known detrimental effect that can significantly deteriorate printing resolution and shape fidelity. This study reveals the underlying mechanism by which process parameters and material properties affect the sedimentation properties of parts fabricated by VAM, considering the intrinsic thermal process and its interaction with polymerization kinetics. It was found that thermally induced changes in material viscosity and polymerization parameters played an essential role in regulating sedimentation behavior. Lowering the ambient and initial printing temperatures can increase viscosity resistance and thus weaken the sedimentation phenomenon, whereas a longer printing time adversely influences part sinking. Optimal thermal conditions that simultaneously ensure low sedimentation and a relatively short printing time should be determined during printing, particularly for thermally thinned materials. Importantly, using the wall-end effect, the model revealed that settlement could be effectively mitigated by solidifying the part near the bottom of the container. The experiments confirmed a reduction of approximately 39.4% in sedimentation displacement. The thermal-solid-fluid coupled model developed in this study offers a valuable tool to guide the design of new photosensitive materials as well as the optimization of process parameters, which is essential to improve the printing outcomes of VAM and thus facilitate its broader applications.

Keywords

Volumetric additive manufacturing (VAM) / Sedimentation / Three-dimensional (3D) printing / Numerical simulation / Parametric analysis

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Yi-Fei Wang, Xiao-Xiao Han, Xiao-Long Zhu, Wei Zhu, Feng Chen. Influence of thermal effects and fluid dynamics on part sedimentation in volumetric additive manufacturing. Advances in Manufacturing 1-22 DOI:10.1007/s40436-026-00599-8

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