Applied Chemical Engineering

Energy-efficient FDM printing of sustainable polymers: Optimization strategies for material and process performance

Subramani Raja

Centre for Sustainable Materials and Surface, Metamorphosis, Chennai Institute of Technology Chennai, India

Rusho Maher Ali

Lockheed Martin Engineering Management, University of Colorado, Boulder, Colorado, 80308, United States

S. Karthikeyan

Department of Mechanical Engineering, Erode Sengunthar Engineering College, Erode, Tamilnadu, 638057, India

Raviteja Surakasi

Department of Mechanical Engineering, Lendi Institute of Engineering and Technology, Jonnada, Vizianagaram, Andhra Pradesh,535005, India

R. Anand

Department of Aeronoutical Engineering, Nehru Institute of Technology, Coimbatore, Tamilnadu, 641008, India

Neelamegam Devarasu

Department of Electronics and Communication Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, 400 feet Outer Ring Road, Avadi, Chennai, 600062, Tamilnadu, India

Sathish T.

Department of Mechanical Engineering, Vel Tech Multi Tech Dr.Rangarajan Dr.Sakunthala Engineering College,Chennai, Tamilnadu, 600062, India

DOI: https://doi.org/10.59429/ace.v7i3.5537

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Abstract

The integration of sustainable polymers in fused deposition modeling (FDM) 3D printing offers a promising pathway toward reducing the environmental impact of additive manufacturing. However, the energy-intensive nature of FDM processes presents a significant challenge to the overall sustainability of this technology. In this study, we explore the use of bio-based and recycled polymers in FDM printing and develop optimization strategies to reduce energy consumption without compromising material and print performance. Our results demonstrate that by systematically optimizing key printing parameters such as extrusion temperature, print speed, and layer height it is possible to achieve up to 20% energy savings. Additionally, we find that novel material formulations and advanced thermal management techniques enhance the mechanical properties of printed objects by up to 15%, all while minimizing energy use. This research not only advances the field of sustainable 3D printing but also provides a framework for the development of next-generation materials and processes that align with the principles of a circular economy.

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