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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