Impact of Print Parameters on Pressure Drop in Turbulent Flow Through 3-D Printed Pipes

Flow conduits made via additive manufacturing, commonly referred to as 3-D printing, are of increasing interest for a variety of industrial applications due to the ability to create unique and conformal flow paths that would not be possible with other fabrication techniques. Fused filament fabrication (FFF) is an additive manufacturing technique that is seeing new interest in the creation of internal flow channels with its ability to print high-temperature polymers and soluble supports. Printing parameter choices in the FFF printing process result in surfaces that can have significant profile differences that may significantly impact the flow characteristics within the conduits. In this study, two print parameters were experimentally studied for turbulent water flow through circular pipes created by fused filament fabrication out of acrylonitrile butadiene styrene (ABS). The print layer orientation relative to the flow was investigated for printing layers parallel, perpendicular, and at 45 degrees from the flow axis. Layer thickness were varied from 0.254 mm to 0.330 mm and all channels were created using soluble support structures. Pressure drops were measured for fully developed flow through pipes with an inside diameter of 5 mm and Reynolds numbers up to 62,000. Results are presented in terms of relative pressure drops as well as the wall surface roughness that would lead to such impacts. These flow-determined grain surface roughnesses are then compared against measurements of print surface roughness.