An Optimal Layout Model of Curved Panels for Using 3D Printing

• Published in: Sustainability Vol. 14; no. 21; p. 13896
• Main Authors: Cha, Minsu, Kim, Chang-Won, Lee, Taehee, Kim, Baek-Joong, Cho, Hunhee, Kim, Taehoon, Lim, Hyunsu
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 01.11.2022
• Subjects: 3-D printers; 3D printing; Analysis; Architecture; Case studies; Curved panels; Energy consumption; Free form; Genetic algorithms; Layouts; Manufacturing; Optimization; Optimization models; Printing; Productivity; South Korea
• ISSN: 2071-1050; 2071-1050
• DOI: 10.3390/su142113896

Recently, the application of 3D printing in the production of curved panels has increased due to the irregular shape of free-form buildings. In general, 3D printing based on additive manufacturing (AM) methods requires various supports that cause a waste of printing materials and an increase in production time. In this study, we proposed a method for printing a pair of panels that can hold each other through the minimal support connected between each panel. However, this printing method causes an additional non-productivity factor called the non-printing path for the nozzle to move between the pair of panels. Therefore, we also developed an optimal layout model that can minimize non-printing paths and used the genetic algorithm (GA) for its calculation. As a result of applying the optimization model proposed in this study through the case study, the non-printing path was reduced by 18.54% compared with that from the existing method, and the non-printing time was reduced by 34.41 h. The total production time, including non-printing time and printing time, was reduced by 3.89%, and the productivity was improved by 4.04%. The model proposed in this study is expected to minimize unproductive factors that occur in the process of manufacturing curved panels and reduce the energy consumption.