Functionality Versus Sustainability for PLA in MEX 3D Printing: The Impact of Generic Process Control Factors on Flexural Response and Energy Efficiency

Abstract

Process sustainability vs. mechanical strength is a strong market-driven claim in Material Extrusion (MEX) Additive Manufacturing (AM). Especially for the most popular polymer, Polylactic Acid (PLA), the concurrent achievement of these opposing goals may become a puzzle, especially since MEX 3D-printing offers a variety of process parameters. Herein, multi-objective optimization of material deployment, 3D printing flexural response, and energy consumption in MEX AM with PLA is introduced. To evaluate the impact of the most important generic and device-independent control parameters on these responses, the Robust Design theory was employed. Raster Deposition Angle (RDA), Layer Thickness (LT), Infill Density (ID), Nozzle Temperature (NT), Bed Temperature (BT), and Printing Speed (PS) were selected to compile a five-level orthogonal array. A total of 25 experimental runs with five specimen replicas each accumulated 135 experiments. Analysis of variances and reduced quadratic regression models (RQRM) were used to decompose the impact of each parameter on the responses. The ID, RDA, and LT were ranked first in impact on printing time, material weight, flexural strength, and energy consumption, respectively. The RQRM predictive models were experimentally validated and hold significant technological merit, for the proper adjustment of process control parameters per the MEX 3D-printing case.

Innovative Strategies for Technical-Economical Optimization of FDM Production

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“…As the adoption of additive manufacturing expands across various industrial sectors, ensuring the optimal performance and cost-effectiveness of fabricated parts becomes increasingly imperative. The studies in [ 21 , 22 , 23 , 24 , 25 , 26 ] have investigated the cost-effectiveness and the environmental impact of additive manufacturing.…”

Novel advancements in additive manufacturing of PLA: A review

“…Meanwhile, PNCs have been fabricated with enhanced thermal and electrical conductivity, improved mechanical and thermal expansion, and increased fire retardancy for automotive, oil and gas, and other versatile applications 137–207 . Finally, it is emphasized that 3‐DPT and 4‐DPT are innovative processing technologies, presenting the future route of the manufacturing sector 208–244 …”

Quantitative Insight into the Compressive Strain Rate Sensitivity of Polylactic Acid, Acrylonitrile Butadiene Styrene, Polyamide 12, and Polypropylene in Material Extrusion Additive Manufacturing

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