Strategic cost and sustainability analyses of injection molding and material extrusion additive manufacturing
Strategic cost and sustainability analyses of injection molding and material extrusion additive manufacturing
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DOI：
10.1002/pen.26256
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发表时间：
2023-01-24
影响因子：
3.2
通讯作者：
Krantz, Joshua
中科院分区：
文献类型：
--
作者：
Kazmer, David;Peterson, Amy M. M.;Krantz, Joshua
对四种不同的塑料制造工艺进行了经济和环境成本评估，包括冷流道和热流道成型，以及库存和升级的材料挤出三维（3D）打印机。较大的库存3D打印机的熔化能力为14.4 ml/h，而带有升级挤出机的较小的打印机的熔化能力为36 ml/h。在这些最大熔化能力下，3D打印的比能耗（SEC）分别为16.5和5.28千瓦时/千克，后者的值不到文献中报道的最低值的50%。即便如此，对这些过程的分析发现，相对于理论最低能量需求，它们的效率只有2.9%和3.8%。相比之下，全电机冷流道和热流道成型的SEC分别为1.28和0.929 kWh/kg，相对于理论最小值，效率分别为9.9%和13.6%。考虑到模具的成本和碳足迹的盈亏平衡分析发现，在生产数量约为70,000个单位时，注塑成型更可取。模型输入的参数分析表明，就碳税激励而言，盈亏平衡数量是稳健的，但高度依赖于模具成本、劳动力成本和零件尺寸。模塑和3D打印样品的尺寸和力学性能也进行了表征和讨论。
Economic and environmental costs are assessed for four different plastics manufacturing processes, including cold and hot runner molding as well as stock and upgraded material extrusion three dimensional (3D) printers. A larger stock 3D printer was found to provide a melting capacity of 14.4 ml/h, while a smaller printer with an upgraded extruder had a melting capacity of 36 ml/h. 3D printing at these maximum melting capacities resulted in specific energy consumption (SEC) of 16.5 and 5.28 kWh/kg, respectively, with the latter value being less than 50% of the lowest values reported in the literature. Even so, analysis of these respective processes found them to be only 2.9% and 3.8% efficient relative to their theoretical minimum energy requirements. By comparison, cold and hot runner molding with an all-electric machine had SEC of 1.28 and 0.929 kWh/kg, respectively, with efficiencies of 9.9% and 13.6% relative to the theoretical minima. Breakeven analysis considering the cost and carbon footprint of mold tooling found injection molding was preferable at a production quantity of around 70,000 units. Parametric analysis of model inputs indicates that the breakeven quantities are robust with respect to carbon tax incentives but highly dependent on mold costs, labor costs, and part size. Dimensional and mechanical properties of the molded and 3D printed specimens are also characterized and discussed.