Optimizing tensile strength and energy consumption for FDM through Mixed-Integer Nonlinear Multi-objective...

Area of Science:

• Additive Manufacturing
• Materials Science
• Sustainable Engineering

Background:

• Fused Deposition Modeling (FDM) is a widely used additive manufacturing technology.
• Optimizing FDM parameters is crucial for balancing material properties and energy efficiency.
• High energy consumption and achieving desired tensile strength are key challenges in FDM.

Purpose of the Study:

• To develop a methodology for optimizing FDM printer parameters.
• To minimize energy consumption (EC) while ensuring a minimum tensile strength (TS) threshold.
• To identify key parameters influencing TS and EC in FDM.

Main Methods:

• Design of Experiments (DoE) using Taguchi and Response Surface analysis.
• Development of a Mixed-Integer Nonlinear Multi-Objective Optimization model.
• Experimental validation of optimized parameters using fabricated specimens.

Main Results:

• Identification of critical FDM parameters affecting both TS and EC.
• Determination of optimal parameter settings balancing TS and EC.
• Experimental validation showed less than 5% error in TS and less than 2% error in EC.

Conclusions:

• The proposed methodology effectively optimizes FDM parameters for reduced energy consumption.
• The study demonstrates a viable approach to achieve sustainable additive manufacturing.
• The optimized parameters ensure that tensile strength requirements are met or exceeded.