Accurate simulation of the printing process is essential for improving print quality, reducing waste, and optimizing the printing parameters of extrusion-based additive manufacturing. Traditional additive manufacturing simulations are very compute-intensive and are not scalable to simulate even moderately-sized geometries. In this paper, we propose a general framework for creating a digital twin of the dynamic printing process by performing physics simulations with the intermediate print geometries. Our framework takes a general extrusion-based additive manufacturing G-code, generates an analysis-suitable voxelized geometry representation from the print schedule, and performs physics-based (transient thermal and phase change) simulations of the printing process. Our approach leverages parallel adaptive octree meshes for both voxelated geometry representation as well as for fast simulations to address real-time predictions. We demonstrate the effectiveness of our method by simulating the printing of complex geometries at high voxel resolutions with both sparse and dense infills. Our results show that this approach scales to high voxel resolutions and can predict the transient heat distribution as the print progresses. This work lays the computational and algorithmic foundations for building real-time digital twins and performing rapid virtual print sequence exploration to improve print quality and further reduce material waste.

翻译：精确模拟打印过程对于提升打印质量、减少浪费以及优化基于挤出的增材制造打印参数至关重要。传统的增材制造模拟计算密集度高，且无法扩展到中等尺寸几何体的仿真。本文提出一种通用框架，通过结合中间打印几何体进行物理仿真，构建动态打印过程的数字孪生。该框架接收通用基于挤出的增材制造G代码，根据打印计划生成适用于分析的体素化几何表示，并执行基于物理（瞬态热与相变）的打印过程仿真。我们利用并行自适应八叉树网格实现体素化几何表示与快速仿真，以支持实时预测。通过在高体素分辨率下模拟具有稀疏与密集填充的复杂几何体打印，验证了方法的有效性。结果表明，该方法可扩展至高体素分辨率，并能预测打印过程中的瞬态热分布。本研究为构建实时数字孪生与快速虚拟打印序列探索奠定了计算与算法基础，从而提升打印质量并进一步减少材料浪费。