Geometry-driven analysis and assessment of energy efficiency in fused filament fabrication

This contribution uses geometry-driven analysis and assessment to investigate the energy efficiency of fused filament fabrication (FFF), where the bending strength remains constant while the cross-sectional form varies. Components with Q, I, U and T cross-sections were printed in two size series. Each size series had the same section modulus (W) value and was produced using the same slicing and machine settings. Measurements included total energy consumption, printing time, and sample mass, from which specific energy consumption was derived. The tool path dynamic is specified by the acceleration and deceleration times extracted from the G-code. The analysis investigates whether the cross-sectional form, at a constant W value, causes systematic differences in energy consumption and efficiency. The extent to which these differences can be explained by printing time is also investigated, as well as under which conditions the contribution of the movement profile becomes decisive. Based on these results, design guidelines are derived that align with propertybased and resource-efficient development, complementing parameter-oriented optimization with a macro-geometric lever.