Energy Utilization Analysis and Optimization of Corrective Insoles Manufactured by 3D Printing

The foot orthotic insole market is forecast to surpass a value of 3.6 billion USD by 2021. This vast industry continues to rely on foam milling and other subtractive methods of manufacturing, which have proven to be wasteful and inefficient. Leaps in digital manufacturing have enabled the technology to enter a plethora of industries, with the promise of increased customization accompanied with reduced waste generation. Despite boasting these valuable traits, the explosive proliferation of 3D printing in conjunction with mounting pressure to incorporate sustainable practices, means that research must be focused on maximizing the material and energy efficiency of the technology. This paper employs a Design of Experiments (DoE) approach for the optimization of two prefabricated insoles, adjusting percentage infill and layer height to obtain data regarding the effects of these parameters on print time, filament usage volume, and energy consumption. Key conclusions formed from the study were that infill density is the dominant factor effecting material consumption and power usage, whereas layer height has the greatest influence on production time. The data presented in this study has the potential to aid not only in the development of mass producible additive manufactured (AM) insoles, but also to advance the understanding of the environmental impact of AM technologies

Algorithm for Applying 3D Printing in Prototype Realization – Case: Enclosure for an Industrial Pressure Transmitter

Additive manufacturing technology helped many organizations to save money in the product design process by reducing prototype costs, and also by providing a means for early evaluation and decision making. The idea of this paper is to design an electronics enclosure for an intelligent industrial pressure transmitter, using the additive technology. All enclosure elements are made on a 3D printer WANHAO duplicator i3 plus, using PLA materials. The enclosure realization, from CAD drawings to the finished model, enables a designer to correct existing errors, or make certain modifications as required by end-users. A process is described that enables designers to review their decisions at any stage of product realization, thus providing much more freedom in rapid prototyping. In this example, the advantages and disadvantages of additive manufacturing over conventional manufacturing are outlined. Some deficiencies have also been observed, such as mechanical damage to surfaces, burning of surfaces, tearing of prints, and surface roughness. To mitigate such irregularities, both mechanical and chemical finishing methods were used. The example confirmed that the finishing methods can affect the final enclosure dimensions and shape. Further prototype development should focus more on print quality, which depends on the shape of surfaces, the accuracy of the geometry, the uniformity of structure and shape, material density, and the resolution of details.Proceedings of the International Conference of Experimental and Numerical Investigations and New Technologies, CNNTech 2020, vol 153, June 29 – July 02, Zlatibor, Serbia