Printing Cost Optimization for 3D Manufacturing

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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