The 3D printers integrated with fused filament fabrication (FFF) are highly valued worldwide because of their properties, which include fast proofing, compatibility with various materials, and low printing cost. The competitiveness of FFF can be enhanced by improving printing quality. However, due to the increasing sustainability issues worldwide, there is an urgent need to lower energy consumption. In this study, we focused on fan rate, printing speed, nozzle temperature, build plate temperature, and layer thickness as factors that directly impact the dimensional accuracy, carbon dioxide emissions, and printing cost of FFF printers. Several single-objective and multiobjective optimization tasks were performed using the Taguchi method and desirability approach to implement sustainable manufacturing decisions. In single-objective optimization, the inner width, outer width, material cost, and labor cost were most easily affected by the layer thickness. The outer length, carbon dioxide emissions, and electricity cost were significantly affected by the build plate temperature. In multiobjective optimization, a different set of printing parameters can be used to optimize dimensional accuracy, carbon dioxide emissions, material cost, labor cost, and electricity cost. This study helps users to obtain optimal solutions under different optimization requirements to cope with diverse manufacturing characteristics.
Highlights1. Comprehensively evaluated the performance of a low-cost spring-assisted mechanism for the separation process.2. The Taguchi method was used to obtain the parameters that minimize the separation force and time.3. The spring-assisted mechanism demonstrated better manufacturing stability than the pulling-up or tilting mechanism. 4. A linear regression equation was established to predict the separation force of specific geometric shapes and areas to greatly reduce the calculation costs and time.
In the field of additive layer manufacturing, constrained-surface digital light processing has attracted considerable attention due to its high precision and low material loss. During the process of separating the cured layer from the resin tank, the high separation force generated by the pulling-up mechanism increases the printing failure rate and reduces the life cycle of the resin tank. Although changing the separation mechanism can significantly reduce the separation force, this often has the tradeoff of high equipment costs. This study comprehensively evaluated the performance of a low-cost spring-assisted mechanism for the separation process. The Taguchi method was used to confirm the variability of the spring-assisted mechanism and obtain the parameters that minimize the separation force and time. The spring-assisted mechanism was then applied to printing different geometric shapes and areas, and the results demonstrated better manufacturing stability than the pulling-up or tilting mechanism. A linear regression equation was established to predict the separation force of specific geometric shapes and areas to greatly reduce the calculation costs and time.
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