In recent years, the manufacturing industry has been under significant pressure to adopt more environmentally friendly practices. Metal additive manufacturing (AM), commonly known as 3D printing, is no exception. This technology is praised for its ability to reduce waste and improve energy efficiency compared to traditional subtractive manufacturing methods. However, there are still several challenges to be addressed to ensure that metal AM is as sustainable as possible. In this article, let’s explore the sustainable practices that can be implemented in metal additive manufacturing to reduce waste and energy consumption without compromising efficiency and profitability.
Optimising Design for Sustainability
One of the most significant advantages of metal AM is its ability to produce complex geometries that are often impossible to create with traditional manufacturing methods. By leveraging this capability, manufacturers can design parts that use less material without sacrificing strength or functionality. This practice, known as lightweighting, not only reduces material usage but also decreases energy consumption during the use phase, particularly in the automotive and aerospace industries where weight is a critical factor [1].
Material Efficiency and Recycling
Metal AM inherently produces less waste than subtractive manufacturing, as it adds material layer by layer to create an object. Nonetheless, there is still some waste in the form of support structures and waste powder. To minimize this, sustainable practices include recycling the metal powder that is not fused during the printing process.
Energy Consumption
The energy consumption of metal AM is a complex issue. While the printing process itself can be energy-intensive, the overall energy savings from lightweight components and the consolidation of assemblies into fewer parts can result in a net reduction in energy use over the product’s lifecycle. To further reduce energy consumption, manufacturers can implement energy-efficient machines and optimize printing processes to run at lower temperatures when possible. Additionally, using renewable energy sources to power AM operations can significantly reduce the carbon footprint of the manufacturing process [2].
Post-Processing Reduction
Post-processing in metal AM, including heat treatment and surface finishing, can be resource-intensive. To address this, researchers and manufacturers are developing new techniques to reduce the need for post-processing. For example, advancements in print bed technologies aim to improve the surface quality of printed parts, potentially eliminating the need for additional finishing steps [3].
Life Cycle Assessment (LCA)
Conducting a Life Cycle Assessment is crucial for evaluating the environmental impact of metal AM processes comprehensively. LCA helps identify the stages of the manufacturing process that have the highest environmental impact and provides a basis for making informed decisions to improve sustainability [4].
Industry Collaboration and Standardisation
Collaboration within the industry can lead to the development of standardized practices for sustainability in metal AM. Sharing knowledge and best practices can accelerate the adoption of sustainable methods. Moreover, working with regulatory bodies to establish guidelines for sustainability can ensure that the entire industry moves towards greener manufacturing practices.
Takeaway
In conclusion, metal additive manufacturing presents a unique opportunity to enhance sustainability in the manufacturing sector. By optimizing designs for reduced material usage, recycling materials, managing energy consumption, minimizing post-processing, conducting life cycle assessments, and fostering industry collaboration, manufacturers can significantly reduce the environmental impact of their operations. While challenges remain, the potential for metal AM to revolutionize sustainable manufacturing is vast. It is imperative for the industry to continue to innovate and implement these practices to ensure a balance between environmental responsibility, efficiency, and profitability.
References
[1] “The Costs and Benefits of Additive Manufacturing.” https://www.ncbi.nlm.nih.gov/pmc/articles/PMC5524380/
[2] “Tools for Sustainable Product Design: Additive Manufacturing.” 2019, https://www.ccsenet.org/journal/index.php/jsd/article/view/6456
[3] “Microstructure Investigation of Selective Laser Melting 316L Stainless Steel Parts Exposed to Laser Re-Melting.” ScienceDirect, 2011, https://www.sciencedirect.com/science/article/pii/S2214860416300933.
[4] “Metal Additive Manufacturing: A Review.” ScienceDirect, 2014, https://www.sciencedirect.com/science/article/pii/S2214860416300933
[5, 6] artificial images created with DALL-E by the InsideMetalAdditiveManufacturing.com team