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Taha Najam

 

Taha Najam

King, Fahd University of Petroleum and Minerals, Germany

Abstract Title: Process Parameters on Residual Stress Distribution in ABS 3D Printing- A Computational Study

Biography:

Taha Najam is a MSc. student in Aerospace Engineering at KFUPM with a background in Mechanical Engineering and extensive experience in additive manufacturing and material characterization. Formerly a lab CAE Engineer, Taha specialized in computational modeling, thermo mechanical behavior, and composite testing, implementing tools like ANSYS, ABAQUS, and COMSOL. Taha also contributed to UAV development at a leading Pakistani company, focusing on design and rapid prototyping. Currently, their research explores induction heating for dynamic adhesive joints, aiming to advance aerospace and automotive applications through innovative material solutions.

Research Interest:

Residual stresses play a crucial role in determining the mechanical performance and dimensional accuracy of 3D-printed components. This study employs thermo mechanical finite element analysis, using the Genova 3D Printing Analysis Tool, to investigate how printing speed and layer height influence residual stress distribution in Acrylonitrile Butadiene Styrene (ABS) parts. Simulations incorporate transient heat transfer, material deposition, and solidification behavior to model the additive manufacturing process. Results show that higher printing speeds increase residual stress due to insufficient cooling time between layers, while larger layer heights reduce stress by minimizing interfaces but compromising part resolution. These findings emphasize the trade-offs between print quality and mechanical integrity, underscoring the need for parameter optimization. This work provides a computational framework for predicting residual stress, offering insights to enhance the structural performance and reliability of FDM-based thermoplastic parts.