Optimizing time in additive manufacturing: a hybrid fused deposition modeling and photopolymerization approach

Abstract

Purpose This study aims to address the challenge of reducing the build time of a fused deposition modeling (FDM) system while maintaining part strength, proposing a hybrid technique combining photopolymerization and FDM. Design/methodology/approach For developing the hybrid system, a standard FDM machine was modified to incorporate necessary components so that the whole system can be operated with a single interface; further, the samples were fabricated with conventional and modified process to evaluate the efficacy of the developed system, to determine the extent of time reduction that the proposed methodology can obtain, additionally different sort of 3D models were selected and their build time was compared. Findings The modified hybrid mechanism can successfully fabricate parts with a modified G-code. The simulation of the technique shows that a reduction of 34%–87% can be achieved for simpler models such as cube while a reduction ranging from 30.6%–87.8% was observed for complex models. An increase in strength of 6.58%, 11.51% and 37.32% was observed in X, Y and Z directions, along with a significant increase in toughness as compared with FDM parts for parts fabricated with the developed mechanism. Practical implications The modified mechanism could be used for fast fabrication purposes, which could be very useful for serving situations such as emergency health care, rapid tooling. Originality/value This research contributes a novel hybrid technique for additive manufacturing, offering a substantial reduction in build time without compromising mechanical properties, even increasing them.