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The impact of the risk of build failure on energy consumption in additive manufacturing

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  • Han Wang
  • Martin Baumers
  • Shreeja Basak
  • Yinfeng He
  • Ian Ashcroft

Abstract

Additive manufacturing (AM), also known as 3D printing, is associated with significant promise in the manufacturing sector. However, it has been shown that the risk of build failure has a substantial impact on the costs of AM and that this results from a relatively high level of process instability. Importantly, for such a promising technology, the effects of the risk of build failure on energy consumption have not yet been studied, which creates a significant gap in the knowledge of the real environmental performance of AM. This research addresses this gap by investigating the energy consumption of AM subject to the possibility of build failure. This is done by constructing a novel expected energy consumption model, integrating process energy consumption, the energy embedded in the raw material, and the probability of build failure as a function of the number of layers deposited. Model parameters are obtained from a series of build experiments conducted on the AM technology variant polymeric laser sintering, also known as laser powder bed fusion of polymers. The energy consumption model shows that the risk of build failure accounts for a substantial share of overall expected energy consumption, amounting to up to approximately 31% at full capacity utilization. Additionally, this paper uncovers a complex relationship between the risk of build failure and efficiency gains in per unit energy consumption resulting from increasing levels of capacity utilization (Supporting Information S1).

Suggested Citation

  • Han Wang & Martin Baumers & Shreeja Basak & Yinfeng He & Ian Ashcroft, 2022. "The impact of the risk of build failure on energy consumption in additive manufacturing," Journal of Industrial Ecology, Yale University, vol. 26(5), pages 1771-1783, October.
  • Handle: RePEc:bla:inecol:v:26:y:2022:i:5:p:1771-1783
    DOI: 10.1111/jiec.13318
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    References listed on IDEAS

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    1. Martin Baumers & Luca Beltrametti & Angelo Gasparre & Richard Hague, 2017. "Informing additive manufacturing technology adoption: total cost and the impact of capacity utilisation," International Journal of Production Research, Taylor & Francis Journals, vol. 55(23), pages 6957-6970, December.
    2. Jeremy Faludi & Martin Baumers & Ian Maskery & Richard Hague, 2017. "Environmental Impacts of Selective Laser Melting: Do Printer, Powder, Or Power Dominate?," Journal of Industrial Ecology, Yale University, vol. 21(S1), pages 144-156, November.
    3. Yao Li & Guozhu Jia & Yang Cheng & Yuchen Hu, 2017. "Additive manufacturing technology in spare parts supply chain: a comparative study," International Journal of Production Research, Taylor & Francis Journals, vol. 55(5), pages 1498-1515, March.
    4. Christopher Tuck & Richard Hague & Neil Burns, 2007. "Rapid manufacturing: impact on supply chain methodologies and practice," International Journal of Services and Operations Management, Inderscience Enterprises Ltd, vol. 3(1), pages 1-22.
    5. Martin Baumers & Chris Tuck & Ricky Wildman & Ian Ashcroft & Richard Hague, 2017. "Shape Complexity and Process Energy Consumption in Electron Beam Melting: A Case of Something for Nothing in Additive Manufacturing?," Journal of Industrial Ecology, Yale University, vol. 21(S1), pages 157-167, November.
    6. Grazia Maria Cappucci & Martina Pini & Paolo Neri & Marta Marassi & Elena Bassoli & Anna Maria Ferrari, 2020. "Environmental sustainability of orthopedic devices produced with powder bed fusion," Journal of Industrial Ecology, Yale University, vol. 24(3), pages 681-694, June.
    7. Karel Kellens & Martin Baumers & Timothy G. Gutowski & William Flanagan & Reid Lifset & Joost R. Duflou, 2017. "Environmental Dimensions of Additive Manufacturing: Mapping Application Domains and Their Environmental Implications," Journal of Industrial Ecology, Yale University, vol. 21(S1), pages 49-68, November.
    8. Baumers, Martin & Dickens, Phill & Tuck, Chris & Hague, Richard, 2016. "The cost of additive manufacturing: machine productivity, economies of scale and technology-push," Technological Forecasting and Social Change, Elsevier, vol. 102(C), pages 193-201.
    9. Ruihuan Ge & Joseph Flynn, 2022. "A computational method for detecting aspect ratio and problematic features in additive manufacturing," Journal of Intelligent Manufacturing, Springer, vol. 33(2), pages 519-535, February.
    10. Jan Holmström & Matthias Holweg & Siavash H. Khajavi & Jouni Partanen, 2016. "The direct digital manufacturing (r)evolution: definition of a research agenda," Operations Management Research, Springer, vol. 9(1), pages 1-10, June.
    11. Sun, Cheng & Wang, Yun & McMurtrey, Michael D. & Jerred, Nathan D. & Liou, Frank & Li, Ju, 2021. "Additive manufacturing for energy: A review," Applied Energy, Elsevier, vol. 282(PA).
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