Present and Future Sustainability Development of 3D Metal Printing

Abstract

Additive manufacturing (AM), also known as 3D printing is a relatively new concept and promising technology for industrial production. It is important to investigate the environmental impact of the AM process in light of the environmental critical situation of the Earth. The elimination of some costly prefabrication processes such as molding or post-fabrication stages such as machining and welding required in traditional manufacturing methods favor the AM process and provide beneficial economic advantages. Furthermore, the reduction of manufacturing steps contributes to environmental protection through fewer operations, less material, and energy consumption, and reduced transportation. This study is a review for the assessment of environmental impact and life cycle of some well-known AM technologies for manufacturing metallic parts and components. The fabrication of a pump impeller is simulated through a well-known metal production AM technology and casting process for direct comparison. Life Cycle Assessment (LCA) is applied to measure the environmental impact in five different stages of pump impeller lifetime with the two different fabrication processes. AM compared to casting has an environmental impact reduction potential of 15%, 20%, 65%, 20%, and 10% respectively in Global Warming Potential (GWP), Acidifications Potential (AP), Water Aquatic Eco-toxicity Potential (FAETP), Human Toxicity Potential (HTP), and Stratospheric Ozone Depletion (ODP). Using hydroelectricity and renewable electricity mitigate the environmental impact of the AM process in premanufacturing and manufacturing stages temporarily until the advancement of AM technology for consuming less energy. Recommendations for future research to enhance the environmental sustainability of the AM process is proposed as outcomes of this study.

Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective

“…Modern technology has also enabled multi-material and multicolor printing, making it possible to create complex and practical designs in a single print. The use of hydropower and renewable electricity can temporarily reduce the environmental impact of the AM process in the pre-production and production stages until AM technology is developed to reduce energy consumption [274,276,277].…”

“…on the life cycle assessment of the AM process, optimizing key parameters for an efficient result, and increasing the production speed of the AM process. This will also improve the economics of the AM process by reducing the cost of producing the required parts [277]. 4.…”