Energy and Emission Estimation Uncertainty in Fused Deposition Modeling for a Job-Shop

Solid freeform fabrication has the potential to affect both financial and environmental concerns for manufacturing enterprises. However, when planning for installation of a new machine tool, accurate energy usage estimation relies heavily on the data and model selections of the estimator. This project used a variety data sources and model decision options to examine the spread of energy consumption and global warming potential estimates for a fused deposition modeling machine. In addition to primary and secondary data sources, the use of similar machines was explored as proxy estimates for the target machine. A Monte Carlo simulation was constructed to vary the model selections, machine utilization, and data sources. The results indicated data sources and model decisions had large effects on the output and that most model estimates were low.