Printing Cost Optimization for 3D Manufacturing

Over the past four decades, 3D printing- also called additive manufacturing-has evolved from a tool mainly used for making prototypes into powerful technology transforming industries worldwide. It works by constructing objects layer digital designs. This has redefined how we design, produce, and think about products. What began in 1980s as way to quickly test product ideas matured innovation. Modern printing is revolutionizing manufacturing delicate parts metals, plastics, ceramics, even with biological components. Its versatility paving unique possibilities across including healthcare, aerospace, construction, education, fashion. Instead of molding or carving bulk materials, produces layer, utilizing only what required. ensures less waste, more precision enables produce complex, customized designs at reduced cost. Thus, not driving greater efficiency but promoting sustainable manufacturing. One transformative aspects it facilitates shifting mass production small scale custom For example, one can create prosthetics surgical models, tailored per requirement. construction are building ... Read More

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This study investigates a hybrid manufacturing approach that combines 3D printing and injection molding to extend the limitations of each individual technique. Injection is often limited by high initial tooling costs, long lead times, restricted geometric flexibility, whereas 3D-printed molds tend suffer from material degradation, extended cooling lower surface quality. By integrating into injection-molding process, this method enables production complex geometries with improved cost-efficiency. The demonstrated using range polymeric materials, including ABS, nylon, polyurethane foam-each selected enhance mechanical thermal performance final products. Finite element (FEM) analysis was conducted assess distribution, deformation, stress during manufacturing. Results indicated both temperature remained within safe operational limits for materials. An economic revealed substantial cost savings compared fully components, establishing as viable scalable alternative. offers broad industrial applicability, delivering enhanced properties, design reduced costs.

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(1) Background: Optimizing infill density in 3D-printed PLA parts reduces material usage, cost, and waste. This study examines mechanical behavior the initial hydration stages. The findings provide valuable data for numerical simulations engineering applications additive manufacturing. (2) Methods: specimens were printed with densities of 100%, 75%, 25%. Mechanical tests, including tensile compression one-hour stress-relaxation at 2% strain conducted. digital image correlation method was used to obtain fields on samples surface under loading. properties, elastic modulus, strength values, Poissons ratio, assessed. Hydrolytic degradation effects over one month also evaluated. (3) Results: Lowering reduced ultimate (from 60.04 2.24 MPa 26.24 0.77 MPa), Youngs modulus 2645.05 204.15 1245.41 83.79 compressive 26.59 0.80 21.83 1.01 ratio 0.32 0.30). A 40% mass reduction (form 100% 25% density) resulted a 56% decrease 53% modulus. 31% observed samples. Stress relaxation decreased significantly from 75% density, further reductions having minimal impact. Hydrated samples showed no... Read More

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Manufacturing 3D printed lenses for luminaries using additive manufacturing techniques like fused deposition modeling (FDM) to provide design flexibility and reduce cost compared to traditional molding methods. The process involves inputting a lens template with transmission scattering profile into the printer controller. It then deposits parallel layers of transparent polyamide material onto a surface to build the lens. Post-printing steps like adding fillers or tinting the material can further customize the lens properties. Building the lens in layers allows complex shapes without molds.

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Fused deposition modeling (FDM) is widely applied in industries such as automotive, aerospace, and healthcare; however, it limited by print quality, material consumption, process efficiency. Artificial intelligence (AI) a game-changing technology that intended to overcome limitations. In this review, the use of AI FDM 3D printing, with special application real-time error detection, optimization, predictive maintenance, generative design, discussed detail. allows monitoring printing process, which leads dynamic adjustments improve reliability, minimize wastage, enhance structural strength. Efforts have been made on review addressing capability AI-based solutions downtime, setting enable mass production complex, customized parts. Furthermore, potential fully autonomous AI-integrated systems foreseeable future discussed. This integration significant leap towards development efficiency, flexibility for industrial applications.

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Objectives: This systematic review aimed to evaluate the cost, production time, clinical performance, and patient satisfaction of 3D printing workflows in prosthodontics compared conventional subtractive methods. Methods: Following PRISMA guidelines, a search electronic databases was performed identify studies published between 2015 2025 that directly digital additive with analogue or workflows. Studies were eligible if they included prosthodontic treatments such as dentures, crowns, implant-supported prostheses reported at least one relevant outcome. The primary outcomes time efficiency, accuracy (e.g., marginal adaptation, fit), satisfaction. Included methodologically evaluated using MINORS scale risk bias assessed ROBINS-I RoB 2 tools. Results: Seven met inclusion criteria. Overall, demonstrated reduced cost comparison Clinical generally comparable superior, particularly regarding adaptation fit. Patient favourable most studies, although reporting varied. Long-term follow-up limited, which constrains interpretation sustained performance. Conclusions: These findings suggest can ser... Read More

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A simplified process for 3D printing metal parts using fused filament fabrication (FFF) technology that integrates debinding, sintering, and heat treatment into a single operation to reduce processing time and cost. The key innovation is a novel feedstock material containing metal powder, binders, and optional reinforcements that can be extruded into filaments. The filaments are printed, then thermally treated in one step to degrade the binders, sinter the metal, and heat treat the part. The simplified process eliminates separate debinding, sintering, and heat treatment steps. The novel feedstock material enables uniform metal dispersion, consistent properties, and simplified processing compared to conventional FFF metal printing.

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Additive manufacturing system for powder-based 3D printing that reduces weight, cost, and lead exposure compared to conventional shielding methods. The system has an improved shielding mechanism to block ionizing radiation like X-rays generated during powder melting. Instead of thick solid lead walls, the shielding is split into an upper fixed part and a movable lower part. This allows only moving the lower part during printing since the upper part covers the rest. The lower part has thin spaced sheets that mesh together to create a labyrinth structure slowing radiation reflection. This reduces mass and movement compared to solid walls.

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Additive manufacturing (AM) has been gaining increased traction in the industry due to its ability fabricate prototypes and end use parts low volumes at a much lower cost compared conventional processes. There research select an AM process appropriate for fabricating particular parts. However, there is little extant machines even though growing number of with interesting topologies, structures, systems. This paper proposes methodology that aims assist Technical Experts selecting machine Fused Filament Fabrication (FFF). The built around weighted Technique Order Preference by Similarity Ideal Solution (TOPSIS), which uses concept relative closeness attribute weights rank machines. Monte Carlo simulations sensitivity analysis evaluate impact randomizing scoring, perturbing assigned, probability distributions used model human decision variability. were applied three case studies, five FFF seven attributes, top ranked specific part found be largely robust.

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ABSTRACT Plastic pollution, driven by the overuse of plastics and inadequate waste management, poses severe environmental health risks. Despite potential benefits recycling, rates remain low due to high costs centralized recycling systems associated greenhouse gas emissions. Motivated this challenge, study explores reuse plastic for 3D printing as a viable sustainable alternative. A Brabender melt mixer was used combine discarded bags highdensity polyethylene. The resulting composite processed into filaments using singlescrew extruder. Dumbbellshaped specimens were then created extrusion following ASTM D412 specifications. Mechanical properties tested Universal Testing Machine, morphological features examined via Scanning Electron Microscopy. goal is reduce pollution encourage innovative practices. Our approach integrates with Finite Element Analysis accelerate product development minimize material waste, enabling rapid prototyping design optimization. Optimized prototypes fabricated through efficient use. 5 wt% blend demonstrated superior tensile strength thermal stability ... Read More

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A method for fabricating metal parts using selective powder melting with reduced energy consumption and faster production rates compared to conventional methods. The method involves selectively melting powder layers to build the part using a laser or electron beam. After depositing a layer, a lower-energy beam is used to surface melt and consolidate the layer before adding the next one. This reduces the beam power needed for melting while still bonding the layers. The lower energy surface melting also helps layer deposition. This saves energy and time compared to fully melting each layer. The method enables fabricating high-temperature, high-quality metal parts using selective powder melting with lower cost and faster speed.

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Reducing the build volume of an additive manufacturing apparatus like selective laser melting (SLM) or selective laser sintering (SLS) to enable smaller part builds and reduce material usage. The solution involves inserting a module into the build chamber that has a smaller build chamber and a separate dosing chamber. A mechanism links the build platform movement to the dosing piston, so when the platform lowers for a new layer, the piston raises to dispense the right amount of powder. This allows using the smaller build chamber without needing less powder per layer. The dosing chamber can have a larger cross-sectional area to account for powder spreading and shrinkage.

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A printing cartridge for 3D printing that aims to minimize waste of expensive printing material by maximizing material usage and preventing overfilling. The cartridge has a container to hold the printing material, a pump to dispense the material, and a sensor to track the level of material in the container. The cartridge can control the amount of material dispensed based on the sensor readings, preventing overfilling. This allows using up the material in the cartridge more completely and minimizing waste. The sensor data can also be used to optimize slicing parameters and prevent underfilling.

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ABSTRACT As a way of recycling epoxy thermoset materials, they were blended with polycaprolactone (PCL) and processed in the form filament to be used for fused deposition modeling (FDM) 3D printing. Three different materials considered: labcured resin, epoxy/PCL blend, commercial composite containing fiberglass (FR4). These three thermosets milled mixed pure PCL. The distribution PCL matrix was analyzed by Fourier Transform Infrared Spectroscopy (FTIR) coupled microscope. filler FR4 DGEBA adequately distributed matrix. rheological study anticipated good adhesion between layers, without clogging at printing temperatures. model also predicted buckling. Because that, external assistance (PLA) required obtain appropriate printed samples, avoiding mechanical properties specimens determined tensile tests compared injection molded specimens. It observed that incorporation enhanced Young's modulus Very similar results obtained injected samples. proposed method could significant interest employing waste as costeffective reinforcement fuse materials.

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A method for additively manufacturing components with overhanging features that avoids the need for extensive support structures. The method involves connecting a removable support structure to the overhanging section of the component using very small connection points. The connection points are so small that they prevent complete melting through from the support structure to the component during additive manufacturing. This allows the support structure to be removed after printing without damaging the component. The small connection points are used instead of larger supports that would require post-processing to remove. The method enables manufacturing of overhanging features without extensive support structures, reducing post-processing time and cost.

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Additive manufacturing (3D printing) method with corrugated layers that have varying height along the length. This allows reducing material usage compared to flat layers with the same thickness and width. The corrugated layers have a constant cross-sectional area defined by thickness and width. Transition layers with lower height connect the corrugated layers. This allows smoothing height variations between adjacent corrugated layers. The corrugated layers can have greater height than flat layers formed by the printer with the same thickness and width.

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In advanced manufacturing technologies, Additive Manufacturing (AM) stands out for its potential to revolutionize production processes. However, assessing the efficiency and productivity of AM machines remains a significant challenge. This research work presents novel framework generating dataset calculate Overall Equipment Effectiveness (OEE) additive machines. The proposed OEE-3D printing systematically captures Key Performance Indicators (KPIs) including availability, performance, quality metrics specific By integrating data acquisition techniques with real time monitoring systems, ensures accurate collection relevant operational data. outlines methodology, procedures, validation techniques, k-nearest neighbours, support vector machine Naive Bayes learning algorithms utilized predicting OEE values, both inclusive exclusive environmental parameters, pertaining machine. findings demonstrate capability this methodology yield practical insights drive continuous improvement in sector. Correlation analysis within study revealed strong positive relationships between availability performa... Read More

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Using data-driven surrogate models like neural networks to replace physics-based solvers for simulating the output of 3D printers. The surrogate models learn the mapping between the initial and final states of a 3D printing droplet deposition process. They are trained using data generated by physics-based simulations or measured during actual printing. This allows faster, real-time prediction of the final 3D printed shape compared to time-consuming physics-based solvers. The surrogate models can accurately capture the complex physics of droplet deposition and substrate interaction without the computational overhead of numerical integration.

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Fused Deposition Modeling (FDM) is widely used in additive manufacturing. The main limitations of 3-Dimentisonal (3D) printing are the expansive cost material and its low strength as compared to traditional molding process. supported was more expensive because extrusion high surface roughness nature 3D printed objects principal reason for mechanical property weakness. To eliminate such problems, a pellet-based printer coupled with layup fiber technique introduced this preliminary study. obtained result indicated that sample produced by had highest machine direction. A reduction tensile found at another raster angle. After considering differences between carbon (CF) formats, it chopped ineffective terms strength. At same time, fabric type continuous could promote better properties. When analyzing ratio maximum strength/fiber weight, should be noted presented reinforced efficiency.

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Combined matrix optical lens for UV 3D printers that improves uniformity and efficiency of UV light exposure for high precision 3D printing. The lens design reduces the number of LED units needed to illuminate the LCD screen by using double-sided optics. It also allows customization of lens size based on application requirements to optimize cost and performance.

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Determining locations for support structures in additive manufacturing build parts. The system examines the geometrical characteristics of each segment of a building part at a candidate position relative to the energy source. It determines support locations based on factors like the angle of incidence of each segment relative to the energy source. This allows precise determination of which segments require support to achieve good quality. Reducing unnecessary support can reduce the total amount of support material used in the build process.

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Optimizing additive manufacturing processes by dynamically adjusting fabrication conditions based on object shape. The method involves dividing the object into small elements, sorting them by position type (e.g., curved, flat, edge), and setting fabrication conditions specific to each type. This allows customization of parameters like laser power, speed, etc., for different regions to improve efficiency and prevent defects like lack of fusion or burning through.

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An in-situ material regeneration system and method for additive manufacturing, such as 3D printing, enables recovery, reconditioning, and reuse of used powders and liquids collected during the AM process. The system and method involve extracting portions of the powder/liquid at various stages, such as after deposition, wetting, and binding, into separate containers. This allows targeted regeneration processes for each type of material. The collected powders/liquids are regenerated separately or mixed and then reused in subsequent print jobs. The in-situ regeneration reduces waste and material costs compared to discarding and replacing used powders/liquids.

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3D printable parts with integral threads that can be produced in a single print without supports. The key is using a minimum 45 degree angle for the thread flanks, which allows overhangs that can be printed without support material. This enables printing complex parts like screw threads in one piece without separate assembly, reducing cost and complexity compared to conventional manufacturing.

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Method for preparing an additive manufacturing program that reduces support structures in additive manufacturing processes. The method involves dividing the 3D model into layers, calculating overhang angles or lengths for each layer, and subdividing layers with overhang angles or lengths below certain thresholds. This allows reducing support structures while maintaining manufacturing quality.

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A 3D printing system with a multi-material feeding device to improve efficiency and reduce costs when using multiple materials in sequential layers. The system has a main printing chamber with a reservoir for the current material. Below the reservoir are separate recovery tanks for each material, connected by valves. After finishing a layer with a material, open the valve to that recovery tank and let the excess flow in. Then close the valve and switch to the next material. This recycles the unused material instead of mixing it together.

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Optimizing 3D printing speed for complex components without sacrificing quality by selectively using faster fabrication speeds for certain layers. The method involves splitting the component into two parts, one printed at a normal speed and the other at a faster speed. This allows thicker layers to be printed faster while maintaining overall thickness. The optimization is done by finding an orientation that maximizes the number of layers that can be printed faster. The method improves manufacturing time/mass ratio by balancing speed and quality for complex components.

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Printing slices of a 3D component model to reduce the time and resources needed to generate a complete 3D print. The method involves receiving a 3D model of a component, an output structure definition, and segmenting the model into slices. Then, for each slice, the method generates a printing layer that includes an arrangement of one or more slice instances of the slice according to the output structure definition. This allows printing a single layer at a time, rather than printing the entire model in one go, which can significantly reduce the time and resources needed.

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A multi-material 3D printing system that improves material efficiency and reduces costs by efficiently recycling excess material between printing jobs. The system has multiple recovery tanks below the build plate that are connected via valves. After completing a print job with one material, the valve to that tank is opened to let the excess material drain into the recovery tank. This prevents mixing of different materials during recycling. Then the valve is closed and the next material is loaded for the next print job.

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Optimizing the mix of fresh and recycled build material for 3D printing to reduce waste and improve part quality. The mix ratio is dynamically adjusted based on factors like packing density and print height to balance fresh vs recycled material. This allows increasing the amount of recycled material without degrading part properties. It prevents excessive aging of the recycled material by using a variable mix ratio that considers factors like packing density and print height.

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Reducing the large quantity of 3D data that typically has to be sent to a 3D printer during the printing process, thereby making 3D printing systems and processes more efficient, faster and less costly.

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A system to optimize material usage in 3D printing by monitoring and analyzing print conditions along with residual material levels. The system collects data on print layers, material usage, and patterns. It then analyzes and compares the print and residual material data using weighted formulas and morphological range assignments. This detailed analysis allows guiding measures to be made that rationally increase material utilization and optimize resource usage.

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A method for 3D printing multi-material models that reduces material waste and cost by reusing remaining material. The method involves smoothly transitioning between printing the auxiliary structure with leftover material and the main structure with the correct material. When a color change occurs during printing, instead of discarding the leftover material, the print head moves to the auxiliary structure to finish printing it using the remaining material. This allows reusing the leftover material instead of wasting it. After the auxiliary structure is completed, the print head returns to the main structure to continue printing using the correct material.

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A system to manage 3D printers that considers the unique features of 3D printing versus 2D printing. The system collects job execution history from 3D printers and simulates the impact of factors like layer thickness, filling density, and infill pattern on factors like print time, material usage, and power consumption. By simulating these changes, the system can calculate and display the savings in resources and productivity that would result from adjusting 3D printer settings. This provides a 3D printer-specific way to report and compare cost, resource, and productivity savings from different printing conditions.

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Optimizing 3D printing processes by intelligently managing powder supply for better efficiency and yield. The method involves forecasting powder supply levels based on current usage and predicting future demands. It then adjusts print parameters, schedules, and powder ratios to balance primary new powder with recycled powder. This helps avoid shortages, optimize recycling, and minimize waste. The system tracks powder levels, alerts when primary sources run low, and recommends actions to maintain sufficient powder for ongoing and future prints.

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3D printing support generation that reduces the amount of support material needed to print 3D objects. The method involves dynamically identifying overhanging surfaces in a 3D model and generating support posts that connect the overhanging surfaces to the print bed. This allows the 3D printer to print the object without support material where possible, reducing the amount of material needed and improving print quality.

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Non-cement based cementitious material for 3D printing that has faster setting times and lower costs compared to cement-based materials. The material is made by combining fly ash, slag powder, silica fume, lithium silicate, polyacrylic acid water reducer, and graphene oxide in specific proportions. The graphene oxide improves toughness and strength, while the polyacrylic acid water reducer enhances workability. This allows 3D printing of complex structures without collapsing. The material's components are weighed separately, mixed, and dispersed to create a non-cement based cementitious material suitable for 3D printing.

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Efficiently generating job files for 3D printing by dividing the preparation process into two steps. The first step is creating a reusable intermediate file called the Part-to-Build file. This file contains the necessary manufacturing data extracted from the CAD model, like orientation, support, feature, and slicing. The second step is generating the actual job file using the Part-to-Build file, exposure strategy, and nesting. This allows avoiding repeated calculation and input for each job.

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Reducing material consumption in 3D printing while preventing deformation of the printed object. The method involves calculating the required support regions based on the cross-sectional data of the object layers and determining the appropriate support type based on the load applied from above. This allows for optimized support placement that minimizes material usage while maintaining structural integrity.

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Optimizing lattice structures in 3D printing to enable creating objects with customized mechanical properties. The method involves partitioning a 3D model into lattice templates based on functional specifications for desired mechanical properties. The templates are assigned to a uniform grid structure inside the object based on their material behaviors. This generates a printable lattice that can smoothly transition between different material zones when 3D printed. The lattice templates are generated, assigned, and optimized to avoid abrupt property changes between neighboring sections. This allows fabricating objects with tailored mechanical properties using additive manufacturing.

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Combining multiple small 3D printing models within the printer's size range, printing them together, and then disassembling the combined object into the original models. This saves printing resources and improves quality compared to separately printing tiny models. The method involves analyzing the models' contours to find optimal combos, stacking them for printing, and then disassembling using the connecting supports.

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Optimizing scheduling of 3D printing tasks with conflicting objectives using a genetic algorithm. The optimization considers factors like cost, resource usage, and print quality. The method involves using a non-dominated sorting genetic algorithm with an elite strategy to find the best tradeoff solutions among the conflicting objectives. This allows finding an optimal schedule for a set of 3D printing tasks that balances factors like cost, resource usage, and print quality.

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Generating support structures for 3D printing that can be selectively altered or removed before printing to reduce the need for post-processing. The support structures are automatically generated under overhanging areas and in cavities of the 3D model that are not naturally supported. The user can interact with a graphical interface to add, delete, or modify the generated supports before printing. This allows optimizing the support structure for the specific 3D model and printing conditions, reducing the amount of unnecessary support material needed.

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A 3D printing system that recycles excess printing material to reduce waste and lower costs. The system collects excess material during printing and filters out consolidated polymerization particles. It then recycles the remaining uncured material back into the printing process. This allows reusing the extruder feedstock instead of disposing of it. The recycled material can be returned to the printhead or mixed with fresh material to reduce waste and lower costs compared to fully disposing of the excess.

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A method to optimize 3D printing of objects by simulating and analyzing slicing directions before actual printing. The method involves slicing the 3D model in multiple directions, analyzing the slices for cost and quality, generating printing recommendations based on the analysis, and transmitting the recommendations to the printer. This allows virtual simulation and evaluation of different slicing directions to find the optimal ones for print quality and cost before actually printing.

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Optimizing 3D printing parameters to meet time and cost constraints when printing complex objects. The method involves identifying a target print time or cost, obtaining resource costs/times, modifying print parameters like material, thickness, resolution, and details to stay within the target without exceeding the resource limits. This allows prioritizing factors like cost vs detail vs material when choosing print settings.

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Determining an efficient manufacturing process for producing a mix of customized products with different specifications in on-demand printing. The method involves calculating costs for each manufacturing process and selecting the optimal combination of processes based on cost. This allows efficient production of customized orders with varied specifications by determining the most cost-effective sequence of processes for the mix of products.

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Efficient 3D printing using metals, plastics, resins, and other materials that reduces cost while still produces a quality product. The key ideas are: 1. Using shapes as the unit of analysis instead of the 3D file itself. This allows optimizing the printing process based on the shape of the object rather than just slicing the file into layers. 2. Eliminating support structures that require post-processing by printing the object without supports. 3. Using a non-"to-weldable" base plate to simplify part removal and reduce post-processing. 4. Optimizing the X, Y, and Z dimensions of the layers to improve speed and accuracy. 5. Allowing variable layer thicknesses to further optimize speed and accuracy. 6. Using laser defocusing to enable a variety of spot sizes without complex optics. 7. Placing the 3

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