Fused Filament Fabrication Three-Dimensional Printing: Assessing the Influence of Geometric Complexity and Process Parameters on Energy and the Environment

Fused filament fabrication (FFF) 3D printing has been recently adopted in various industries and production processes. Three-dimensional printing (3DP) has gained significant popularity and is being adopted in schools, universities, and fabrication labs, as well as in science, technology, engineering, and mathematics (STEM) education curricula. The aim of this study is to evaluate the energy consumption and environmental impacts of multiple parts with different complexity levels based on various process parameters through FFF printing. This paper focuses on three material filaments: polylactic acid (PLA), tough PLA (T-PLA), and acrylonitrile butadiene styrene (ABS). The influence of geometric complexity, layer height, density, infill pattern, speed, and temperature on energy and the environment will be analyzed through a life-cycle assessment approach. Moreover, this study provides a set of guidelines for 3DP users in education for the energy-efficient and sustainable use of 3D printers. Our results reveal that for the proposed geometries, an energy increase of 8% is recorded for PLA when transitioning from the simple geometry to the very complex one. However, for ABS and T-PLA, no change in energy values due to geometric change is observed. Layer height is found to be the most influential parameter on energy consumption, with an increase of 59%, 54%, and 61% for PLA, ABS, and T-PLA, respectively. Printing temperature, on the other hand, is found to be the least influential parameter on energy and the environment. Furthermore, PLA is found to be the most environmentally friendly material, followed by ABS and T-PLA in terms of climate change, human toxicity, and cumulative energy demand impact categories. However, for the ozone depletion category, ABS contributes the most to environmental damage compared to T-PLA. The results suggest that PLA can be used for visual and prototype models, whereas ABS and T-PLA serve as good candidates for complex end-use applications and functional parts. The presented guidelines will assist 3DP users in the adequate and optimal use of 3DP technology in order to achieve resource efficiency, energy savings, and environmental sustainability.