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Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing

Owen Harding, Christian Griffiths, Andrew Rees, Dimitrios Pletsas

Polymers, Volume: 15, Issue: 8, Start page: 1874

Swansea University Authors: Owen Harding, Christian Griffiths, Andrew Rees, Dimitrios Pletsas

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DOI (Published version): 10.3390/polym15081874

Abstract

Fused Filament Fabrication (FFF) 3D printing is an additive technology used to manufacture parts. Used in the engineering industry for prototyping polymetric parts, this disruptive technology has been adopted commercially and there are affordable printers on the market that allow for at-home printin...

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Published in: Polymers
ISSN: 2073-4360
Published: MDPI AG 2023
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URI: https://cronfa.swan.ac.uk/Record/cronfa63265
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last_indexed 2024-11-15T18:01:16Z
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Used in the engineering industry for prototyping polymetric parts, this disruptive technology has been adopted commercially and there are affordable printers on the market that allow for at-home printing. This paper examines six methods of reducing the energy and material consumption of 3D printing. Using different commercial printers, each approach was investigated experimentally, and the potential savings were quantified. The modification most effective at reducing energy consumption was the hot-end insulation, with savings of 33.8&#x2013;30.63%, followed by the sealed enclosure, yielding an average power reduction of 18%. For material, the most influential change was noted using &#x2018;lightning infill&#x2019;, reducing material consumption by 51%. The methodology includes a combined energy- and material-saving approach in the production of a referenceable &#x2018;Utah Teapot&#x2019; sample object. Using combined techniques on the Utah Teapot print, the material consumption was reduced by values between 55.8% and 56.4%, and power consumption was reduced by 29% to 38%. 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spelling 2023-05-22T15:19:28.2189293 v2 63265 2023-04-27 Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing 8a76eda8492895711393e66631d15c4a Owen Harding Owen Harding true false 84c202c256a2950fbc52314df6ec4914 Christian Griffiths Christian Griffiths true false e43e88c74976e714e1d669a898f8470d Andrew Rees Andrew Rees true false 63535c7a4ffa2bcfdb80aa43158a76a0 Dimitrios Pletsas Dimitrios Pletsas true false 2023-04-27 ACEM Fused Filament Fabrication (FFF) 3D printing is an additive technology used to manufacture parts. Used in the engineering industry for prototyping polymetric parts, this disruptive technology has been adopted commercially and there are affordable printers on the market that allow for at-home printing. This paper examines six methods of reducing the energy and material consumption of 3D printing. Using different commercial printers, each approach was investigated experimentally, and the potential savings were quantified. The modification most effective at reducing energy consumption was the hot-end insulation, with savings of 33.8–30.63%, followed by the sealed enclosure, yielding an average power reduction of 18%. For material, the most influential change was noted using ‘lightning infill’, reducing material consumption by 51%. The methodology includes a combined energy- and material-saving approach in the production of a referenceable ‘Utah Teapot’ sample object. Using combined techniques on the Utah Teapot print, the material consumption was reduced by values between 55.8% and 56.4%, and power consumption was reduced by 29% to 38%. The implementation of a data-logging system allowed us to identify significant thermal management and material usage opportunities to minimise power consumption, providing solutions for a more positive impact on the sustainable manufacturing of 3D printed parts. Journal Article Polymers 15 8 1874 MDPI AG 2073-4360 3D printing, fused filament fabrication, fused deposition modelling, power efficiency, manufacturing optimisation, polylactic acid (PLA) 2 4 2023 2023-04-02 10.3390/polym15081874 http://dx.doi.org/10.3390/polym15081874 COLLEGE NANME Aerospace, Civil, Electrical, and Mechanical Engineering COLLEGE CODE ACEM Swansea University 2023-05-22T15:19:28.2189293 2023-04-27T15:21:34.0214787 Faculty of Science and Engineering School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering Owen Harding 1 Christian Griffiths 2 Andrew Rees 3 Dimitrios Pletsas 4 63265__27248__35738d4386634410add2e71e2246693e.pdf 63265.pdf 2023-04-27T15:29:39.3136536 Output 2632238 application/pdf Version of Record true 2023 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/). true eng https://creativecommons.org/licenses/by/4.0/
title Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing
spellingShingle Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing
Owen Harding
Christian Griffiths
Andrew Rees
Dimitrios Pletsas
title_short Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing
title_full Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing
title_fullStr Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing
title_full_unstemmed Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing
title_sort Methods to Reduce Energy and Polymer Consumption for Fused Filament Fabrication 3D Printing
author_id_str_mv 8a76eda8492895711393e66631d15c4a
84c202c256a2950fbc52314df6ec4914
e43e88c74976e714e1d669a898f8470d
63535c7a4ffa2bcfdb80aa43158a76a0
author_id_fullname_str_mv 8a76eda8492895711393e66631d15c4a_***_Owen Harding
84c202c256a2950fbc52314df6ec4914_***_Christian Griffiths
e43e88c74976e714e1d669a898f8470d_***_Andrew Rees
63535c7a4ffa2bcfdb80aa43158a76a0_***_Dimitrios Pletsas
author Owen Harding
Christian Griffiths
Andrew Rees
Dimitrios Pletsas
author2 Owen Harding
Christian Griffiths
Andrew Rees
Dimitrios Pletsas
format Journal article
container_title Polymers
container_volume 15
container_issue 8
container_start_page 1874
publishDate 2023
institution Swansea University
issn 2073-4360
doi_str_mv 10.3390/polym15081874
publisher MDPI AG
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering
url http://dx.doi.org/10.3390/polym15081874
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description Fused Filament Fabrication (FFF) 3D printing is an additive technology used to manufacture parts. Used in the engineering industry for prototyping polymetric parts, this disruptive technology has been adopted commercially and there are affordable printers on the market that allow for at-home printing. This paper examines six methods of reducing the energy and material consumption of 3D printing. Using different commercial printers, each approach was investigated experimentally, and the potential savings were quantified. The modification most effective at reducing energy consumption was the hot-end insulation, with savings of 33.8–30.63%, followed by the sealed enclosure, yielding an average power reduction of 18%. For material, the most influential change was noted using ‘lightning infill’, reducing material consumption by 51%. The methodology includes a combined energy- and material-saving approach in the production of a referenceable ‘Utah Teapot’ sample object. Using combined techniques on the Utah Teapot print, the material consumption was reduced by values between 55.8% and 56.4%, and power consumption was reduced by 29% to 38%. The implementation of a data-logging system allowed us to identify significant thermal management and material usage opportunities to minimise power consumption, providing solutions for a more positive impact on the sustainable manufacturing of 3D printed parts.
published_date 2023-04-02T02:42:21Z
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