A sustainable approach to large scale additive manufacturing : workflow development and design guidelines

Abstract

The global population increase has driven demand for tools, goods, and services. To meet this demand sustainably, industry must prioritize environmentally friendly manufacturing methods. Additive manufacturing, an eco-beneficial method, can revolutionize modern industry by reducing waste, minimizing emissions, enabling localized manufacturing, and offering design flexibility. Recent advancements in robotic technology have overcome size and movement constraints, allowing for larger-scale and faster production. Polymer-based additive manufacturing dominates the market, but improved pellet extruders that can extrude cost-efficient pellets at high speeds are being developed to increase deposition rates. This technology has the potential to enhance manufacturing efficiency, reduce costs, and shorten lead times, promoting sustainability. However, further refinement is required, particularly in dedicated software solutions and design guidelines. This thesis proposes an integrated workflow for robotic additive manufacturing, encompassing all stages of software development in a single program with high mass customization capacity. Laboratory testing has validated the workflow, introducing design considerations for large-scale additive manufacturing. The research contributes to the development of integrated software solutions and design guidelines, facilitating more sustainable and efficient manufacturing processes.