Optimization of Additive Manufacturing for Mass Production through Standardized Modularity Strategy for High-Volume FDM

Abstract This paper addresses the emerging industrial need to optimize production chains and reduce lead times using Additive Manufacturing (AM). While AM is empirically associated with higher production times and costs compared to traditional Injection Molding (IM), this study proposes a flexible production strategy utilizing “Standardized Modularity.” By discretizing a geometric part into functional modules—specifically a non-critical “Base” and a high-precision “Top” module—production parameters are optimized for each section. A comparative economic analysis between Fused Deposition Modeling (FDM) and Injection Molding was conducted for batch sizes ranging from 10,000 to 100,000 units. The study experimentally validates the modular approach using an UP! PLUS 2 printer and ABS material, testing various interlocking tongue-and-groove patterns. Results indicate that FDM remains cost-competitive with IM for series up to 15,000 units. Furthermore, the modular division strategy achieved a production cost reduction of approximately 13% compared to single-iteration printing, while mechanical testing confirmed that optimized modular interfaces retain up to 94% of the monolithic part’s tensile strength.