Evaluating 3D Printers Using Data Envelopment Analysis

Journal of Integrated Design and Process Science

Injection molding (IM) is considered to be one of the most important mass production processes for plastic products. A substantial amount of research has been directed towards finding settings for the IM process variables as well as the optimal location of the injection gates. These objectives have been mostly approached through the optimization of performance measures (PMs) as functions of the process' variables. Several times, however, these process design and part or tooling design objectives have been addressed independently, rather than in an integrated fashion. The use of computer-aided engineering (CAE) has played a pivotal role in trying to achieve these objectives. The aim of this work is to demonstrate a method based on CAE, statistical testing, artificial neural networks (ANNs), and data envelopment analysis (DEA) to find the optimal compromises between multiple PMs to prescribe the settings of IM process variables and the location of the injection gate. A case study ...

Additive manufacturing (AM) is expanding the manufacturing capabilities. However, quality of AM produced parts is dependent on a number of machine, geometry and process parameters. The variability of these parameters affects the manufacturing drastically and therefore standardized processes and harmonized methodologies need to be developed to characterize the technology for end use applications and enable the technology for manufacturing. This research proposes a composite methodology integrating Taguchi Design of Experiments, multi-objective optimization and statistical process control, to optimize the manufacturing process and fulfil multiple requirements imposed to an arbitrary geometry. The proposed methodology aims to characterize AM technology depending upon manufacturing process variables as well as to perform a comparative assessment of three AM technologies (Selective Laser Sintering, Laser Stereolithography and Polyjet). Results indicate that only one machine, laser-based Stereolithography, was feasible to fulfil simultaneously macro and micro level geometrical requirements but mechanical properties were not at required level. Future research will study a single AM system at the time to characterize AM machine technical capabilities and stimulate pre-normative initiatives of the technology for end use applications.

Polymers , 2022

Fused deposition modeling (FDM) is the most economical additive manufacturing (AM) technology available for fabricating complex part geometries. However, the involvement of numerous control process parameters and dimensional instabilities are challenges of FDM. Therefore, this study investigated the effect of 3D printing parameters on dimensional deviations, including the length, width, height, and angle of polylactic acid (PLA) printed parts. The selected printing parameters include layer height, number of perimeters, infill density, infill angle, print speed, nozzle temperature, bed temperature, and print orientation. Three-level definitive screening design (DSD) was used to plan experimental runs. The results revealed that infill density is the most consequential parameter for length and width deviation, while layer height is significant for angle and height deviation. The regression models developed for the four responses are non-linear quadratic. The optimal results are obtained considering the integrated approach of desirability and weighted aggregated sum product assessment (WASPAS). The optimal results include a layer height of 0.1 mm, a total of six perimeters, an infill density of 20%, a fill angle of 90°, a print speed of 70 mm/s, a nozzle temperature of 220 °C, a bed temperature of 70 °C, and a print orientation of 90°. The current study provides a guideline to fabricate assistive devices, such as hand and foot orthoses, that require high dimensional accuracies.

Proceedings of the Design Society: International Conference on Engineering Design

In practical design work, a designer needs to consider the feasibility of a part for a manufacturing using additive manufacturing (AM) instead of conventional manufacturing (CM) technology. Traditionally and by default parts are assumed to be manufactured using CM and using AM as an alternative need to be justified. AM is currently often a more expensive manufacturing method than CM, but its employment can be justified due to number of reasons: improved part features, faster manufacturing time and lower cost. Improved part features means usually reduced mass or complex shape. However, in low volume production lower manufacturing time and lower part cost may rise to the most important characteristics.In this paper, we present a practical feasibility model, which analyses the added value of using AM for manufacturing. The approach is demonstrated in the paper on four specific parts. They represent real industrial design tasks that are ordered from an engineering office company. These ...

2021

The 3D printing technology is one of the technologies that is developing currently. This machine can make products easily, quickly, and precisely. 3D printing is used to print models, prototypes/modeling, teaching aids for education, health support devices, product design, and many more in 3D shapes. Fused Deposition Modeling (FDM) is the most popular among others 3D printing techniques. In simple concept, it does not need maintenance regarding solvents or glue. The spare parts can be found easily and cheaply. In this research, we create objects by using Autodesk inventor that is called human denture. Then, it converted to G-Code using Simplyfy3D software version 4.1.2. The G-Code data is used in the 3D printer for making the product. We select parameters to print the product. In this study, we find the optimal parameters of the effect of shrinkage and hardness of the product. The 3 parameters are in this study namely; layer height, print speed, temperature print. The material of h...

2019

Dimensional printing object to produce accurate geometry in accordance with the planned. The process parameters investigated are layer height, print speed, perimeter shells and polishing time. Test specimens made with polymaker polysmooth TM material refer to ASTM D995-08 using 3D Printer type Fused Deposition Modelling (FDM). The measurement data were analyzed using ANOVA with design type 2 factorial level and design 4 factorial interactions (4FI) modelled by Design Expert ® software. The result of ANOVA is known that the factors significantly (α = 0.05) have an effect on the geometry of 3D printing object and the optimum parameter combination that is height layer=0.14 mm, print speed=51.73 m s, perimeter shells=3 mm with polishing time=20 minutes.

2000

This paper reports on an application of Data Envelopment Analysis (DEA) to compare products which vary in excellence along a number of dimensions, and for each of which there might be a number of associated ‘cost’. The DEA method is illustrated by comparing 21 CNC(Computer Numerical Control ) lathes for small-size shell production. Potential uses of a DEA analysis of products might be: to assist military buyers who may need to reconcile a diversity of present and future uses in one standardized purchase; in competitors analysis; in determining unexplored market niches: and as a normative model of product excellence against which product purchasing behavior could be compared.

2016

This paper provides a useful insight into the level of quality of several popular Entry-Level 3D Printing (EL3DP) systems. At their best, EL3DPs are able to produce parts for conceptual models and personalised objects. As EL3DP systems become more mainstream, the next generation of machines will continue to provide low ownership costs with a more acceptable degree of quality. This paper presents results of a benchmark analysis of several low-cost material extrusion 3D printers to enable comparison with each other and with more expensive industrial systems. Benchmarking of the parts was carried out using dimensional analysis to determine key performance characteristics as well as aesthetic evaluation by users in terms of the parts being pleasing to look at and to touch. From the study, it was found that a wide variation between different entry-level systems exists, with some of them approaching the performance level of more expensive machines. Many of the EL3DP parts had horizontally...

Journal of Industrial Ecology, 2017

New technologies such as 3D printing, also known as rapid manufacturing or additive manufacturing, are promising technologies to support the aeronautics sector moving toward its ambitious environmental goals. An eco-efficiency method combining life cycle costs and life cycle environmental assessment is developed to support eco-design initiatives in the aeronautics industry that accounts for specific reduction targets. Eco-efficiency results are computed through a normalization procedure and a target-driven trade-off and displayed as an XY diagram. Applied to an aircraft doorstop manufacturing, results show that 3D printing has clear benefits both in terms of costs and environmental impacts compared to conventional machining. Nevertheless, 3D printing equipment costs are still high, and a sensitivity analysis shows that, for lower productivity levels, the optimal scenario relies on the chosen trade-off between environmental impacts and costs reduction.

2020

3D printing technology is developing very fast. One of the technologies that are often encountered is Fused Deposition Modeling (FDM). FDM technology has many advantages, such as easy maintenance, not easily damaged, easy to operate, relatively safer, and relatively cheaper. Much researches on the optimization of the FDM process have been carried out. There is a need to map research results regarding process optimization and the results of FDM technology so that it can provide research opportunities for other researchers to develop this technology. For this reason, this study aims to map the results of research that has been carried out regarding the optimization of the 3D printing process, especially FDM technology. This study uses a qualitative method, namely, a literature review. According to technology and year of publication, some literature is selected to provide relevant and up-to-date results. Based on the literature review that has been done, some process parameters are use...