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Head-to-Head Evaluation of FDM and SLA in Additive Manufacturing: Performance, Cost, and Environmental Perspectives

2025-02-19Text Open access
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datacite.subject.fosEngenharia e Tecnologia
dc.contributor.authorAbbasi, Maryam
dc.contributor.authorANTUNES VAZ, PAULO JOAQUIM
dc.contributor.authorMartins, Pedro
dc.contributor.authorSilva, José
dc.date.accessioned2025-03-24T12:47:04Z
dc.date.available2025-03-24T12:47:04Z
dc.date.issued2025-02-19
dc.description.abstractThis paper conducts a comprehensive experimental comparison of two widely used additive manufacturing (AM) processes, Fused Deposition Modeling (FDM) and Stereolithography (SLA), under standardized conditions using the same test geometries and protocols. FDM parts were printed with both Polylactic Acid (PLA) and Acryloni trile Butadiene Styrene (ABS) filaments, while SLA used a general-purpose photopolymer resin. Quantitative evaluations included surface roughness, dimensional accuracy, ten sile properties, production cost, and energy consumption. Additionally, environmental considerations and process reliability were assessed by examining waste streams, recy clability, and failure rates. The results indicate that SLA achieves superior surface quality (Ra ≈ 2 µm vs. 12–13 µm) and dimensional tolerances (±0.05 mm vs. ±0.15–0.20 mm), along with higher tensile strength (up to 70 MPa). However, FDM provides notable ad vantages in cost (approximately 60% lower on a per-part basis), production speed, and energy efficiency. Moreover, from an environmental perspective, FDM is more favorable when using biodegradable PLA or recyclable ABS, whereas SLA resin waste is hazardous. Overall, the study highlights that no single process is universally superior. FDM offers a rapid, cost-effective solution for prototyping, while SLA excels in precision and surface finish. By presenting a detailed, data-driven comparison, this work guides engineers, product designers, and researchers in choosing the most suitable AM technology for their specific needs.eng
dc.description.sponsorshipFurthermore, we thank the Research Center in Digital Services (CISeD) and the Instituto Politécnico de Viseu for their support. Maryam Abbasi thanks the national funding by FCT—Foundation for Science and Technology, I.P., through the institutional scientific employment program contract (CEECINST/00077/2021)
dc.identifier.citationAbbasi, M., Váz, P., Silva, J., & Martins, P. (2025). Head-to-Head Evaluation of FDM and SLA in Additive Manufacturing: Performance, Cost, and Environmental Perspectives. Applied Sciences, 15(4), 2245. https://doi.org/10.3390/app15042245
dc.identifier.doihttps://doi.org/10.3390/app15042245
dc.identifier.eissn2076-3417
dc.identifier.urihttp://hdl.handle.net/10400.19/9294
dc.language.isoeng
dc.peerreviewedyes
dc.publisherMDPI
dc.relationCentre for Research in Digital Services
dc.relation.hasversionhttps://www.mdpi.com/2076-3417/15/4/2245
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/
dc.subjectadditive manufacturing
dc.subjectdimensional accuracy
dc.subjectenergy consumption
dc.subjectenviron mental impact
dc.subjectfused deposition modeling
dc.subjectproduction cost
dc.subjectreliability
dc.subjectstereolithography
dc.subjectsurface finish
dc.subjecttensile strength
dc.subjectusability
dc.titleHead-to-Head Evaluation of FDM and SLA in Additive Manufacturing: Performance, Cost, and Environmental Perspectivespor
dc.typetext
dspace.entity.typePublication
oaire.awardTitleCentre for Research in Digital Services
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDB%2F05583%2F2020/PT
oaire.citation.issue4
oaire.citation.startPage2245
oaire.citation.titleApplied Sciences
oaire.citation.volume15
oaire.fundingStream6817 - DCRRNI ID
oaire.versionhttp://purl.org/coar/version/c_970fb48d4fbd8a85
person.familyNameANTUNES VAZ
person.familyNameSilva
person.givenNamePAULO JOAQUIM
person.givenNameJosé
person.identifier.ciencia-id351C-9899-0EE7
person.identifier.ciencia-id4A14-D3E7-5B32
person.identifier.orcid0000-0002-1745-8937
person.identifier.orcid0000-0001-7285-8282
person.identifier.scopus-author-id55447844100
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.nameFundação para a Ciência e a Tecnologia
relation.isAuthorOfPublication702e79ee-5b0b-47ff-989d-12e6d8ea1e89
relation.isAuthorOfPublicatione9d8719e-af47-4008-b854-817801bb3964
relation.isAuthorOfPublication.latestForDiscoverye9d8719e-af47-4008-b854-817801bb3964
relation.isProjectOfPublicationa2335235-05b4-404c-a71e-cc37ae7fbf2c
relation.isProjectOfPublication.latestForDiscoverya2335235-05b4-404c-a71e-cc37ae7fbf2c

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