Sustainability-focused optimization of fused-deposition component design and manufacturing

The sustainability of the fused-deposition modeling process and its optimization is studied in this paper using a method in which consideration is simultaneously given to the design of the structural component and its 3Dprinting process. The proposed method is used to determine the mechanical properties of the deposited materials, through an experimental study that follows an experimental design with variable printing parameters. Having recorded the values of the material properties, a topological optimization of each experimental point is performed. Then, the printing processes are designed with the help of a slicing software package and, based on the results, the corresponding key sustainability performance indicators are computed on the basis of the printing parameters. Finally, an optimization process is conducted and the most convenient solution is chosen. Validated using a real case study, the effectiveness of the proposed approach is demonstrated for determining the most suitable choice when design and manufacturing are simultaneously considered through the lens of sustainability.