Parametric optimization for enhancing process sustainability: evidence from fused deposition modeling process

This study examines the process optimization potential for enhancing the sustainability of a manufacturing process, taking the fused deposition modeling process as a case study. First, the survey- and experiment-based approaches were applied to identify the process parameters and their operating ranges, respectively ensuring the desired level of dimensional deviation. Then the association of each control parameter, i.e., printing temperature, layer height, printing speed, and non-printing speed, with each response variable, i.e., electrical energy consumption, indirect CO 2 gas emissions, scrap weight, and production rate, was determined, and used to set the optimization criteria. All control parameters had linear relationships with response variables. Except for printing temperature, all control parameters adversely affected energy consumption and indirect CO 2 emission. Moreover, printing the parts at the optimal conditions helped reduce energy consumption, indirect CO 2 emission, and scrap weight and increase the production rate substantially indicating its enormous potential for improving process sustainability. Graphical abstract