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UWE Bristol Engineering showcase 2015

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Fabian, Tze Fung Ang<br />

BENG (Hons) Mechanical <strong>Engineering</strong><br />

Project Supervisor<br />

Jason Matthews<br />

Green manufacturing<br />

Introduction<br />

In the latest global trend, due to the limited availability of non-renewable resources, global warming, several<br />

improvements in government regulation about the environment status due to the manufacturing process on<br />

compliance and non-compliance cost, public concern and social responsibility have been a big issue toward out<br />

new generation challenge. These are all the general reasons why organizations have recently encouraged on the<br />

campaigns to adopt a green and sustainable practice in the manufacturing industries. In this project, Fused<br />

Deposition Modelling (FDM) 3D-printing has been used as a case study and have been address with a green<br />

manufacturing prospect to point out the problems and solutions have been suggested using the 5 strategies.<br />

Biodegradable material<br />

Fused deposition modelling 3D-printer relies heavily<br />

on using thermoplastic to produce printed products<br />

that are beneficial towards others. Almost all plastics<br />

are non-biodegradable in nature. Non-biodegradable<br />

plastic thrown off in land mines stays right there since<br />

it is not degraded. It cannot be used for other<br />

purposes like biogas production. By choosing the<br />

usage of Polyactic Acid (PLA) and Acrylonitrile<br />

butadiene styrene (ABS) as the thermoplastic material<br />

for the FDM printer will help enhancing the solutions<br />

of substituting the materials as it brings great benefits<br />

towards the ecosystem and better quality productions<br />

can be produced using biodegradable material<br />

Stronger structure product by using same material<br />

Through studying the knowledge from material<br />

science, it has shown that each substance consist of<br />

molecules in it no matter if it is in any state of matter.<br />

By understanding that, it can also show that the<br />

material breaks easily when the material have a higher<br />

air gap between the molecules.<br />

The concept for the solution is to reduce the air gap<br />

between the induced material that can be shown in<br />

the diagram. By doing so, the products that can be<br />

produced are stronger in structure strength and will<br />

solve the problem for not being able to replace other<br />

material for FDM besides thermoplastics.<br />

Energy consumption<br />

Using a fused deposition modelling<br />

3D-printer consumes a big portion<br />

of energy power mainly through<br />

heating of the thermoplastic. Even<br />

though energy conservation<br />

reduces energy services, it can<br />

result in increased environmental<br />

quality, personal financial security<br />

and higher savings. It is at the top of<br />

the sustainable energy hierarchy. It<br />

also lowers energy costs by<br />

preventing future resource<br />

depletion. Two solutions that can be<br />

introduced to solve the problem.<br />

5 strategy for green manufacturing<br />

1) Reduce consumption of material and energy<br />

2) Substitution of input materials<br />

3) Reduce unwanted outputs<br />

4) Convert outputs to inputs<br />

5) Well modelled supply chain structure<br />

Conserving energy<br />

The lack of technology to reduce the<br />

energy consumption of FDM have left<br />

installing sensors to keep track to the<br />

energy usage and having a routine<br />

maintenance on the machine will help<br />

conserve the energy<br />

Solar power generator<br />

Installing solar power generator will<br />

help the FDM to transform into a<br />

self sustaining manufacturing<br />

industries and will save up the cost<br />

of energy since it can generates<br />

own power.<br />

Increasing efficiency<br />

Efficiency is the extent to which time, effort, or cost is well-used for the<br />

intended task or function. The solution to increase the efficiency of the FDM<br />

process is as follow.<br />

Reusing the waste of the products<br />

By reusing the waste products in the<br />

finishing stage will reduce the input<br />

material and improve the output<br />

materials of the whole<br />

manufacturing process. This will<br />

save the cost of the production line.<br />

Reducing error of production<br />

Understanding the cause of the<br />

error is the key towards this study<br />

field. By solving the problem and<br />

minimizing the error, it will result in<br />

an improve quality quicker<br />

production as it is essential to have<br />

a minimum error in the<br />

manufacturing industry.<br />

Project summary<br />

This project strive to seek out the solutions for<br />

addressing the Fused Deposition Modelling (FDM) 3D<br />

printing technology in an extend to green<br />

manufacturing prospect by using the 5 strategies for<br />

green manufacturing to imply on the solutions. Study<br />

and understanding of the ways to examine the<br />

sustainability of the green manufacturing process is<br />

required in order to justify the problems and<br />

generate a conceptual solutions to the technology.<br />

Project Objectives<br />

• Studying the basic product cycle of the<br />

manufacturing process.<br />

• Studying the methods and outcome of the green<br />

manufacturing process that are applicable to the<br />

current market status.<br />

• Study the challenges of the green manufacturing<br />

process.<br />

• Understanding the technical sustainability of the<br />

technology process.<br />

• Understanding the effects that will help out the<br />

eco-environment<br />

• Study the effects of the market sustainability of<br />

the technology.<br />

• Research of the market and environment needs<br />

globally.<br />

• Learning the adaptation on the possibilities of<br />

improvements and the actual application for the<br />

manufacturing industries.<br />

Project Conclusion<br />

In conclusion, this project have meet its aim<br />

by studying various fields of green<br />

manufacturing and have provide a better<br />

knowledge in solving the problems that are<br />

impose through the 5 strategies of green<br />

manufacturing.

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