Sharp Dual-Regime Transition Driven by Bead Morphology in Metal Fused Filament Fabrication: Bead-Resolved Digital Twin Analysis

This repository contains the bead-level thermal simulation data and analysis scripts supporting the findings reported in the paper. Ten GPU-accelerated transient thermal simulations were conducted using a bead-resolved voxel framework, covering two metal–polymer composites (IN718–PLA and Cu–PLA) at three super-ellipse exponents (n = 2.0, 2.7,2.8,2.9 3.0). Per-bead thermal metrics were extracted from the time-resolved temperature fields and are provided here as Excel files. All statistical analyses, figures, and claims in the paper can be reproduced directly from these datasets.