An empirical method for forecasting energy consumption in material extrusion

Additive manufacturing (AM) is one of the most sustainable manufacturing processes since it could build parts directly from a computer-aided design (CAD) model simplifying the production of complex geometries, and they are generally more environmentally friendly using only the exact amount of material. Despite this qualitative consideration, the quantitative convenience in terms of energy consumption has not yet been extensively investigated. In the present paper, a model is proposed to improve understanding of AM energy use by applying a novel classification system for machine components, generating, as a result, the characteristic parameters specific for each material and useful for estimating energy consumption providing a simple tool for the companies that would evaluate the technology convenience considering also the energetical component. The main outcome is represented by the characteristics parameters for the main materials used in the material extrusion process and an approach for evaluating the energy consumption a priori with a prevision error of less than 10%.