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<p>In the material extrusion printing process, the printed part is a layered replica of the solid CAD model, incorporating structural printing settings such as infill pattern, density, and more. Simulation with a solid CAD model alone is an inaccurate approach to predicting the part responses of a 3D-printed component. It is essential to consider the structural printing settings to achieve more accurate analysis. This paper presents a methodology for creating a layered CAD model using G-code file data and a geometric scripting approach, followed by a finite element analysis of the designed model. The G-code file of the object is first processed to extract relevant information. Parametric geometry scripts were written to read the extracted data and generate a layered CAD model. The scripts were tested across various printing settings and part orientations and were found to effectively incorporate the structural printing settings. To validate the effectiveness of the layered CAD model in finite element analysis, two approaches were employed. In the first, simulation results of the layered CAD model were compared with published data for PLA and 316L stainless steel parts printed at various orientations. In the second, ASTM D638 tensile specimens were printed using PLA with three different infill densities. Experimental tensile testing was conducted to determine Young’s modulus, and the results were compared with finite element analysis of the corresponding layered CAD models. The simulated values showed good agreement with the experimental results, with an error margin of less than 15%.</p>

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From G-code to FEA: a geometric scripting approach to design and simulate layered CAD model for material extrusion printed part

  • 期刊论文

  • 发表日期：

    2025年9月18日

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  • Pretesh John,
  • Venkateswara Rao Komma,
  • Skylab Paulas Bhore

摘要

In the material extrusion printing process, the printed part is a layered replica of the solid CAD model, incorporating structural printing settings such as infill pattern, density, and more. Simulation with a solid CAD model alone is an inaccurate approach to predicting the part responses of a 3D-printed component. It is essential to consider the structural printing settings to achieve more accurate analysis. This paper presents a methodology for creating a layered CAD model using G-code file data and a geometric scripting approach, followed by a finite element analysis of the designed model. The G-code file of the object is first processed to extract relevant information. Parametric geometry scripts were written to read the extracted data and generate a layered CAD model. The scripts were tested across various printing settings and part orientations and were found to effectively incorporate the structural printing settings. To validate the effectiveness of the layered CAD model in finite element analysis, two approaches were employed. In the first, simulation results of the layered CAD model were compared with published data for PLA and 316L stainless steel parts printed at various orientations. In the second, ASTM D638 tensile specimens were printed using PLA with three different infill densities. Experimental tensile testing was conducted to determine Young’s modulus, and the results were compared with finite element analysis of the corresponding layered CAD models. The simulated values showed good agreement with the experimental results, with an error margin of less than 15%.