Environmental impacts of rapid prototyping: an overview of research to date

Drizo, Aleksandra; Pegna, Joseph

doi:10.1108/13552540610652393

Cited by 129 publications

(98 citation statements)

References 29 publications

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“…This has significant cost savings potential and it is clear that it qualitatively reduces the environmental impact of 3-D metal printing. Previous work has shown improved constrained sustainability (Reeves, 2009), reduced carbon emissions (Reeves, 2012), reduced environmental impact using 3-D printing for prototyping (Drizo and Pegna, 2006), distributed manufacturing (Kreiger and Pearce, 2013) and global sustainability (Gebler et al, 2014) as compared conventional methods of manufacturing in plastic and metal. Future work should consider a full life cycle analysis of GMAW 3-D printing.…”

Section: Discussionmentioning

confidence: 98%

In situ formation of substrate release mechanisms for gas metal arc weld metal 3-D printing

Haselhuhn

Wijnen

Anzalone

et al. 2015

Journal of Materials Processing Technology

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a b s t r a c tThis study provides an in-depth investigation into low-cost and no-cost substrate release mechanisms that allow gas metal arc weld 3-D printed ER4043 aluminum and ER70S-6 steel parts to be removed from a reusable print substrate with minimal energy. Aluminum oxide, boron nitride, and titanium nitride coatings were evaluated as possible substrate release agents for aluminum printing. Additionally, the in situ formation of substrate release agents such as intermetallics and oxides were tested for both aluminum and steel printing. Testing was performed with a modified Charpy impact tester to remove 3-D printed metal parts from an 1100 aluminum or A36 low carbon steel print substrate to assess the impact energy required for removal. Specimen porosity was measured prior to sectioning and microstructural analysis, hardness traverses were measured across the specimens, and the elastic and shear moduli of the parts were analyzed via ultrasonic methods. All of the employed substrate release mechanisms minimized weld penetration and, in some instances, formed a brittle phase with the print substrate that allowed the specimens to be removed with minimal impact energy. These results thus provide methods with the removal of metal 3-D printed parts from print substrates with no specialized tooling or equipment conducive to distributed manufacturing.

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Section: Discussionmentioning

confidence: 98%

In situ formation of substrate release mechanisms for gas metal arc weld metal 3-D printing

Haselhuhn

Wijnen

Anzalone

et al. 2015

Journal of Materials Processing Technology

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“…73 From the perspective of energy consumption, AM processes are usually not as efficient as conventional manufacturing processes. For example, machine tools are equipped with many peripheral devices; thus, basic power consumption and processing time are two of the main considerations in energy consumption calculations.…”

mentioning

confidence: 99%

A comparison of energy consumption in bulk forming, subtractive, and additive processes: Review and case study

Yoon

Lee

Kim

et al. 2014

Int. J. of Precis. Eng. and Manuf.-Green Tech.

273

109

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In addition to the steps taken to ensure optimal efficiency in industry, significant effort has been directed towards the green and sustainable manufacturing practices. In this paper, we review conventional and state-of-the-art manufacturing technologies to provide insight into energy consumption at the processing level. In the review, collected energy data were summarized for three manufacturing categories: conventional bulk-forming, subtractive, and additive manufacturing (AM) processes. Additive processes, in particular, are strongly emphasized in the Advanced Manufacturing Initiatives proposed recently by the United States government. Currently, the specific energy consumption (SEC) of additive processes is estimated to be ~100-fold higher than that of conventional bulk-forming processes, with subtractive processes showing intermediate values that varied over a wide range in terms of scale. Although SEC may vary with respect to the details, in general, the research showed a negative correlation with respect to the reciprocal logarithmic form of the productivity. In addition to the literature review presented, we performed case studies for the three manufacturing processes, to provide practical examples of energy consumption. Additionally, our results indicated that AM processes may require more extensive evaluation; i.e., an assessment of the entire manufacturing cycle, for more accurate prediction of the subsequent environmental impact.

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“…) and AM waste products (Huang et al. ; Drizo and Pegna ), but without weighing these impacts against energy inputs. Drizo and Pegna () note that very few studies comprehensively measure impacts, such as waste and toxicity, in a way that would allow AM operators and machine designers to determine priorities for sustainability.…”

Section: Introductionmentioning

confidence: 99%

Environmental Impacts of Selective Laser Melting: Do Printer, Powder, Or Power Dominate?

Faludi¹,

Baumers²,

Maskery³

et al. 2016

J of Industrial Ecology

140

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SummaryThis life cycle assessment measured environmental impacts of selective laser melting, to determine where most impacts arise: machine and supporting hardware; aluminum powder material used; or electricity used to print. Machine impacts and aluminum powder impacts were calculated by generating life cycle inventories of materials and processing; electricity use was measured by in-line power meter; transport and disposal were also assessed. Impacts were calculated as energy use (megajoules; MJ), ReCiPe Europe Midpoint H, and ReCiPe Europe Endpoint H/A. Previous research has shown that the efficiency of additive manufacturing depends on machine operation patterns; thus, scenarios were demarcated through notation listing different configurations of machine utilization, system idling, and postbuild part removal. Results showed that electricity use during printing was the dominant impact per part for nearly all scenarios, both in MJ and ReCiPe Endpoint H/A. However, some low-utilization scenarios caused printer embodied impacts to dominate these metrics, and some ReCiPe Midpoint H categories were always dominated by other sources. For printer operators, results indicate that maximizing capacity utilization can reduce impacts per part by a factor of 14 to 18, whereas avoiding electron discharge machining part removal can reduce impacts per part by 25% to 28%. For system designers, results indicate that reductions in energy consumption, both in the printer and auxiliary equipment, could significantly reduce the environmental burden of the process.

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Environmental impacts of rapid prototyping: an overview of research to date

Cited by 129 publications

References 29 publications

In situ formation of substrate release mechanisms for gas metal arc weld metal 3-D printing

In situ formation of substrate release mechanisms for gas metal arc weld metal 3-D printing

A comparison of energy consumption in bulk forming, subtractive, and additive processes: Review and case study

Environmental Impacts of Selective Laser Melting: Do Printer, Powder, Or Power Dominate?

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