A computational framework for optimising Extrusion Blow Moulding: Enhancing material efficiency and reducing waste for industry 4.0

This study presents a computational framework specifically designed to optimise parts produced through the Extrusion Blow Moulding (EBM) processes. By focusing on the crucial phases of the EBM process, namely mould clamping and parison inflation, the framework aims to assist manufacturers in precise material usage control, thereby reducing waste and optimising resources to produce the final parts. The simulation of those phases relies on advanced numerical simulations based on finite strain theory and membrane formulation. The optimisation is carried out iteratively and automatically. This optimisation process involves refining the thickness distributions and modifying initial controlling variables to achieve the desired final result that meets the desired specifications. The framework is evaluated through a series of detailed case studies, which include idealised models of cylindrical-like shape bottles and a practical application involving real-world industrial product with a more complex shape format. The latter study comprises an extensive experimental validation. The obtained results demonstrate the developed framework’s effectiveness in optimising material distribution, resulting in significant reductions in material waste and improvements in the quality of the final product. Moreover, the proposed framework proves to be a valuable tool for integrating EBM processes into Industry 4.0, offering an extensible and efficient solution for manufacturers aiming to enhance EBM production capabilities, while minimising environmental impact.