Strategic cost and sustainability analyses of injection molding and material extrusion additive manufacturing

Economic and environmental costs are assessed for four different plastics manufacturing processes, including cold hot runner molding as well stock upgraded material extrusion three dimensional (3D) printers. A larger 3D printer was found to provide a melting capacity of 14.4 ml/h, while smaller with an extruder had 36 ml/h. printing at these maximum capacities resulted in specific energy consumption (SEC) 16.5 5.28 kWh/kg, respectively, the latter value being less than 50% lowest values reported literature. Even so, analysis respective processes them be only 2.9% 3.8% efficient relative their theoretical minimum requirements. By comparison, all-electric machine SEC 1.28 0.929 efficiencies 9.9% 13.6% minima. Breakeven considering cost carbon footprint mold tooling injection preferable production quantity around 70,000 units. Parametric model inputs indicates that breakeven quantities robust respect tax incentives but highly dependent on costs, labor part size. Dimensional mechanical properties molded printed specimens also characterized discussed.