Process-based modeling of energy consumption for multi-material FDM 3D printing

• Published in: Journal of intelligent manufacturing and special equipment (Online) 2024-08, Vol.5 (1), p.190-202
• Main Authors: Yang, Wenzhen, Liu, Yu, Chen, Jinghua, Chen, Yanqiu, Shang, Erwei
• Format: Article
• Language: English
• Subjects: 3-D printers; Energy analysis; Energy consumption; Fused deposition modeling; Manufacturing; Multi-material 3D printing; Nozzles; Power supply; Printing; Process parameters; Temperature; Thermal energy
• ISSN: 2633-6596; 2633-660X
• DOI: 10.1108/JIMSE-10-2023-0008

Purpose This paper endeavors to create a predictive model for the energy consumption associated with the multi-material fused deposition modeling (FDM) printing process.Design/methodology/approach An online measurement system for monitoring power and temperature has been integrated into the dual-extruder FDM printer. This system enables a comprehensive study of energy consumption during the dual-material FDM printing process, achieved by breaking down the entire dual-material printing procedure into distinct operational modes. Concurrently, the analysis of the G-code related to the dual-material FDM printing process is carried out.Findings This work involves an investigation of the execution instructions that delineate the tooling plan for FDM. We measure and simulate the nozzle temperature distributions with varying filament materials. In our work, we capture intricate details of energy consumption accurately, enabling us to predict fluctuations in power demand across different operational phases of multi-material FDM 3D printing processes.Originality/value This work establishes a model for quantifying the energy consumption of the dual-material FDM printing process. This model carries significant implications for enhancing the design of 3D printers and advancing their sustainability in mobile manufacturing endeavors.