Abstract
Fused deposition modeling (FDM) is one of the important additive layer manufacturing techniques, used to fabricate products from heated polymer materials. Like other manufacturing processes, sustainability interventions are desirable in FDM to attain energy and resource efficiency simultaneously with good product quality. This paper reports the results of investigation conducted by the authors on effect of topology optimization strategy on quality of FDM parts and sustainability of the process. A total of eighteen experiments have been conducted by varying infill pattern and density at three levels each for optimized and unoptimized topology, based on Taguchi L18 technique. Statistical fitness of the data has been insured by ANOVA. Both infill density and pattern have been found the significant parameters. Better mechanical strength has been obtained for topology optimized FDM parts. A set of confirmation experiments have been conducted followed by quantification of sustainability and indicated that improved mechanical properties simultaneously with enhanced sustainability can be achieved via topology optimization in FDM process
Highlights
In last few years, there has been an accelerated growth in demand of additive manufacturing (AM) techniques due to their advantages over conventional manufacturing
The present research studied the effect of topology optimization strategy for anisotropic materials which are used to make Fused deposition modelling (FDM) parts
This research determined that there exists a range of infill densities, 28-to 95%, for a material retention percentage of 60% at which the electrical energy consumption, manufacturing time and material consumption can be reduced without negatively affecting the mechanical performance
Summary
There has been an accelerated growth in demand of additive manufacturing (AM) techniques due to their advantages over conventional manufacturing. Fused deposition modelling (FDM) is an important AM based technique where products are manufactured layer by layer through an extruder from heated polymer materials [1,2,3]. It has widespread applications from prototype manufacturing to rapid tool making. FDM offers a simplified manufacturing-impacts phase which is divided into three stages: filament production, FDM manufacturing, and post-processing [6]. The recycling of auxiliary material is a growing fiend in sustainable AM and some technologies offer to user the ability to convert waste into functional filament
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