A framework to reduce product environmental impact through design optimization for additive manufacturing

Tang, Yunlong; Mak, Kieran; Zhao, Yaoyao Fiona

doi:10.1016/j.jclepro.2016.06.037

Cited by 183 publications

(95 citation statements)

References 19 publications

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“…Such shapes and constructive features could or would not be made with casting, CNC milling, or other conventional manufacturing technologies. This implies that a benchmark with new manufacturing techniques should include designs fulfilling the same function, optimized for the specific manufacturing technique, compared to a conventionally produced product (Tang et al 2016).…”

Section: Introductionmentioning

confidence: 99%

Life cycle assessment of wire + arc additive manufacturing compared to green sand casting and CNC milling in stainless steel

Bekker

Verlinden

2018

Journal of Cleaner Production

122

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Wire and Arc Additive Manufacturing (WAAM) is a metal 3D printing technique based on robotic welding. This technique yields potential in decreasing material consumption due to its high material efficiency and freedom of shape. Empirical measurements of WAAM, using a deposition rate of 1kg/h, were performed on site of MX3D. The measured power consumption per kg stainless steel is 2.72 kW, of which 1.74 is consumed by the welder, 0.44 by the robotic arm, and 0.54 by the ventilation. The material loss was 1.1%. A 98% argon 2% CO2 welding gas was used with a flow of 12 l/min. A cradle-to-gate Life Cycle Assessment (LCA) was performed. To give this assessment context, green sand casting and CNC milling were additionally assessed, through literature and databases. The purpose of this study is to develop insight into the environmental impact of WAAM. Results indicate that, in terms of total ReCiPe endpoints, the environmental impact of producing a kg of stainless steel 308l product using WAAM is comparable to green sand casting. It equals CNC milling with a material utilization fraction of 0.75. Stainless steel is the main cause of environmental damage in all three techniques, emphasizing the importance of WAAM's mass reduction potential. When environmentally comparing the three techniques for fulfilling a certain function, optimized designs should be introduced for each manufacturing technique. Results can vary significantly based on product shape, function, materials, and process settings.

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Section: Introductionmentioning

confidence: 99%

Life cycle assessment of wire + arc additive manufacturing compared to green sand casting and CNC milling in stainless steel

Bekker

Verlinden

2018

Journal of Cleaner Production

122

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“…AM is a significant technological innovation in the field of advanced manufacturing. A number of benefits of AM have been discussed in the literature, ranging from design flexibility, product customization, and minimum raw material utilization to shortening of supply chains and potential reduction of overall environmental impacts [5,[26][27][28][29][30][31]. A comprehensive definition of AM is given by American Society of Testing and Materials as "A process of joining materials to make objects from a 3D model data, usually layer upon layer, as opposed to subtractive manufacturing technologies" [32].…”

Section: Additive Manufacturing Backgroundmentioning

confidence: 99%

“…References Design flexibility with complex geometries [5,7,26,29,[36][37][38][39][40][41][42][43] Reduced environmental impact [7,27,[38][39][40]42,[44][45][46][47][48] Maximum material utilization with lesser waste generation [6,7,27,29,36,41,43,44,46,48,49] Less energy consumption and CO2 emissions [6,14,26,38,39,[43][44][45]48] CAD-to-part in single process without the necessity of tools [6,7,36,41,43,[49][50]…”

Section: Advantages and Opportunitiesmentioning

confidence: 99%

Framework for Life Cycle Sustainability Assessment of Additive Manufacturing

Ribeiro

Matos

Jacinto³

et al. 2020

Sustainability

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Additive manufacturing (AM) is a group of technologies that create objects by adding material layer upon layer, in precise geometric shapes. They are amongst the most disruptive technologies nowadays, potentially changing value chains from the design process to the end-of-life, providing significant advantages over traditional manufacturing processes in terms of flexibility in design and production and waste minimization. Nevertheless, sustainability assessment should also be included in the research agenda as these technologies affect the People, the Planet and the Profit: the three-bottom line (3BL) assessment framework. Moreover, AM sustainability depends on each product and context that strengthens the need for its assessment through the 3BL framework. This paper explores the literature on AM sustainability, and the results are mapped in a framework aiming to support comprehensive assessments of the AM impacts in the 3BL dimensions by companies and researchers. To sustain the coherence of boundaries, three life cycle methods are proposed, each one for a specific dimension of the 3BL analysis, and two illustrative case studies are shown to exemplify the model.

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“…Examples: optimizing the topology design of the components realized through additive manufacturing allowed a remarkable reduction of the impacts compared to CNC milling [48]. Optimizing the speed of injection of the liquid material inside the molds for reducing the connection radii and the voids and the volumes of the sprues [49].…”

Section: M_e_ma-eliminate Machineries (Optimize)mentioning

confidence: 99%

TRIZ-Based Guidelines for Eco-Improvement

Russo

Spreafico

2020

Sustainability

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This paper proposes a set of Eco-guidelines for supporting designers in developing new greener products and processes. The first requirement that a guideline should have is to be sufficiently general to cover every kind of problem and at the same time sufficiently specific to bring the user closer to the solution without requiring too much personal inspiration. This balance was searched by adopting one of the most known systematic innovation techniques: TRIZ (Russian acronym of Theory of Inventive Problem Solving). In the literature, there are many examples of integrations between Eco-guidelines and problem-solving methods, but the solutions that are suggested, however effective, are not necessarily eco-friendly. To overcome this problem, the authors propose a rigorous ontology indicating how to apply a specific problem-solving strategy onto a specific part of the problem, trying to make the user aware of the environmental consequences of his design changes. The result of this work is a set of 59 guidelines. The article explains the birth of each guideline, the way in which they were adapted with respect to the known technique, and the motivation for which they should generate greener solutions, in light of the results of an experiment involving engineering students in real industrial cases.

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A framework to reduce product environmental impact through design optimization for additive manufacturing

Cited by 183 publications

References 19 publications

Life cycle assessment of wire + arc additive manufacturing compared to green sand casting and CNC milling in stainless steel

Life cycle assessment of wire + arc additive manufacturing compared to green sand casting and CNC milling in stainless steel

Framework for Life Cycle Sustainability Assessment of Additive Manufacturing

TRIZ-Based Guidelines for Eco-Improvement

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