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Additive manufacturing is an essential tool in innovative production processes. The extended degrees of freedom offer much potential in usage, construction, and product design. Rising raw material and energy costs, constantly increasing environmental requirements, and the increasing demand for resource-saving products represent a paradigm shift in classic production processes.
In addition to the purely energetic evaluation, developing energy models is a method to determine energy consumption and reduce it in the long term. The specific energy consumption model, also known as the SEC model, allows a quick estimation of energy consumption by multiplying the SEC with a unit like the mass of the workpiece, the manufacturing time, or the exposed area. Here, high dependence on the used machine, the considered peripheral devices, and the geometry are noticeable.
Previous studies, such as those by Kellens et al. and Baumers et al., have laid the basis for understanding the energy demands of PBF-LB/M processes. Various energy models have subsequently been proposed, including those by Paul and Anand, Yi et al., Lv et al., and Hui et al. These models are often limited by their specificity to sub-processes or subsystems. This results in limitations in their applicability to other manufacturing machines or inaccuracies in energy consumption predictions. The simulation accuracy ACC is mostly in the range of 90% with the limitation of small sample sizes. Moreover, nearly, all these models rely heavily on process time information, making the accuracy of their simulations largely dependent on the quality of the underlying time model.
In the following study, two manufacturing machines of the PBF-LB/M process are analyzed and compared with other studies. The aim is to analyze the power and resource consumption to use these data to build an improved energy model with a high accuracy, which can be used as an additional parameter in the adapted design methodology. Furthermore, potential savings are derived from the load curves.
The number of additive manufacturing methods and materials is growing rapidly, leaving gaps in the knowledge of specific material properties. A relatively recent addition is the metal-filled filament to be printed similarly to the fused filament fabrication (FFF) technology used for plastic materials, but with additional debinding and sintering steps. While tensile, bending, and shear properties of metals manufactured this way have been studied thoroughly, their fatigue properties remain unexplored. Thus, the paper aims to determine the tensile, fatigue, and impact strengths of Markforged 17-4 PH and BASF Ultrafuse 316L stainless steel to answer whether the metal FFF can be used for structural parts safely with the current state of technology. They are compared to two 316L variants manufactured via selective laser melting (SLM) and literature results. For extrusion-based additive manufacturing methods, a significant decrease in tensile and fatigue strength is observed compared to specimens manufactured via SLM. Defects created during the extrusion and by the pathing scheme, causing a rough surface and internal voids to act as local stress risers, handle the strength decrease. The findings cast doubt on whether the metal FFF technique can be safely used for structural components; therefore, further developments are needed to reduce internal material defects.
The objective of this study is to allow a better understanding of the role of industry 4.0 technologies, especially filament extrusion technology in the reduction of costs, environmental impact, energy consumption, and the possibility to expand the range of printable materials. The study focuses on the desktop Filament Extruders available in the market now, where these machines are assessed and future possible modifications for these apparatuses are presented. The research leading to the publication of this study consists of a review of the existing literature, in addition, information from different extruders manufacturers’ websites has been used. The study has demonstrated that the extrusion of material at home is still not an exact science, and the process ends up costing the user large sums of money over time. However, there are still limitations to the use of this technology such as the lack of standardized extrusion settings, the necessity of pre-drying the pellets, and the complexity of the extruder cleaning process after each use.
This paper presents a feasibility study for the production of recycled glycol modified polyethylene terephthalate (PETG) material for additive manufacturing. Past studies showed a variety of results for the recycling of 3D-printing material, therefore the precise effect on the material properties is not completely clear. For this work, PETG waste of the same grade was recycled once and further processed into 3D printing filament. The study compares three blend ratios between purchased plastic pellets and recycled pellets to determine the degradation effect of one recycling cycle and possible blend ratios to counter these effects. Furthermore, the results include a commercially available filament. The comparison uses the filament diameter, the dimensional accuracy of the printed test specimen and mechanical properties as quality criteria. The study shows that the recycled material has a minor decrease concerning the tensile strength and Young’s modulus.