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

Area of Science:

• Additive Manufacturing
• Sustainable Engineering
• Materials Science

Background:

• Fused Filament Fabrication (FFF) is a widely adopted 3D printing technology for prototyping and manufacturing.
• Increasing adoption of FFF printers necessitates strategies for reducing their environmental impact.
• Energy and material consumption are key factors influencing the sustainability of 3D printing.

Purpose of the Study:

• To experimentally investigate six distinct methods for reducing energy and material consumption in FFF 3D printing.
• To quantify the potential savings achievable through each method.
• To identify optimal strategies for sustainable 3D printing.

Main Methods:

• Experimental investigation of six energy and material reduction techniques on commercial FFF printers.
• Quantification of energy savings through methods like hot-end insulation and sealed enclosures.
• Assessment of material savings using techniques such as 'lightning infill'.

Main Results:

• Hot-end insulation achieved the highest energy savings (30.63-33.8%), followed by sealed enclosures (18% power reduction).
• 'Lightning infill' demonstrated the most significant material reduction (51%).
• Combined techniques on a 'Utah Teapot' model reduced material by 55.8-56.4% and power consumption by 29-38%.

Conclusions:

• Specific modifications like hot-end insulation and lightning infill offer substantial savings in energy and material for FFF 3D printing.
• A data-logging system aids in identifying thermal management and material usage optimizations.
• Implementing these methods contributes to more sustainable additive manufacturing practices.