Additive manufacturing How sustainable is additive manufacturing?

Related Vendors

voxeljet AG

Stratasys GmbH

EOS GmbH Electro Optical Systems

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

Is additive manufacturing a sustainable production method and how can this technology help improve the ecological footprint? We asked technology providers in 3D printing.

When discussing sustainability and additive manufacturing (AM), three aspects are at the forefront: Firstly, the sustainability of the technologies themselves, considering the supply chain, production and operation of the machines, consumed resources, required energy, and resulting waste streams. Secondly, the impact that additive manufacturing can have on traditional manufacturing chains from a sustainability perspective (for example, through efficiency improvements). And thirdly, the sustainable contribution that additively manufactured components can make during their lifespan.

So, compared to other production methods, is additive manufacturing the more sustainable option? "Unfortunately, it cannot be said that simply, even though it was often claimed not too long ago. However, we at EOS do believe that additive manufacturing can make an important contribution to more sustainable production. Our perspective is also based on our purpose 'Responsible Manufacturing'. We are committed to data-driven discovery of where this is the case and where adjustments may still be needed," explains Björn Hannappel, Head of Sustainability at EOS. In a life cycle analysis, EOS compared the traditional manufacture of glasses with production using 3D printing. "Here we found that the additive manufacturing of the eyeglass frame has up to three times smaller carbon footprint than conventional manufacturing," says Hannappel.

At Stratasys, we call this "Mindful Manufacturing." We rethink the way parts and processes are designed and integrate additive manufacturing into the production cycle where it is most beneficial for our customers.

Rosa Coblens, Vice President of Sustainability at Stratasys

How does AM help improve the ecological footprint?

Whether a process is ecologically sustainable depends significantly on the scope of the investigation. A view that is too narrow or too broad can prove or disprove almost any hypothesis and leaves much room for interpretation. In the case of additive manufacturing, the complexity is compounded by the fact that the technology itself is very multifaceted: there are dozens of methods, hundreds of providers, and thousands of materials. How can this technology help improve the ecological footprint? "At Stratasys, we call this 'Mindful Manufacturing.' We rethink how parts and processes are designed and integrate additive manufacturing into the production cycle where it is most beneficial for our customers," reveals Rosa Coblens, Vice President of Sustainability at Stratasys. In additive manufacturing, (almost) only the material that goes into the component is needed, resulting in significantly less waste. It also allows for designs that require significantly less material overall for equal or even improved performance of the component. "Furthermore, additive manufacturing enables local production, which can shorten supply chains and reduce transport emissions—we see this with many customers who, for example, digitalize spare parts inventories and only produce parts via 3D printing as needed, saving storage space," says Rudolf Franz, CEO of Voxeljet AG.

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Additive manufacturing also enables new, conventionally unmanufacturable components that can allow for significant energy savings through functional integration. "A good example is 3D-printed inductors, which are used in the automotive industry, for example. Integrated cooling channels not only save material during production and extend the lifespan of the component, but also significantly increase efficiency," emphasizes Hannappel.

A crucial factor is the choice of material

The choice of material in additive manufacturing also has a significant impact on the ecological footprint and overall sustainability. "The more materials available for additive manufacturing, the more applications can be addressed. Indirect processes like 3D printing for sand and investment casting have advantages over direct metal printing processes, as significantly more alloys can be cast than printed, thus meeting the demands of multiple industries. Especially in the foundry sector, more and more of our customers are focusing on inorganic, low-emission binders," explains Rudolf Franz. The choice of material affects the performance and durability of the final product. "Materials that extend the product's lifespan can lead to reduced resource consumption over time," says Rosa Coblens. Different materials may require varying amounts of energy in processing, the Vice President of Sustainability at Stratasys further notes. Choosing materials that are more energy-efficient in their production and processing can reduce the overall carbon footprint of AM.

The role of design for additive manufacturing in sustainability

A crucial factor in the sustainability of components in the field of additive manufacturing is the principle of Design for Additive Manufacturing (DfAM). One of the most important advantages of DfAM is the ability to customize components for specific applications. This customization leads to improved performance and efficiency, which in turn reduces energy consumption and waste during the operational phase. By manufacturing components tailored precisely to the specific application, manufacturers can achieve a level of efficiency that is simply not achievable with conventional methods. "Rocket engines are a good example of this. In conventional manufacturing, up to several hundred components had to be individually produced and then assembled, which can be reduced to just a few components through 3D printing, potentially with enhanced stability or improved properties," Hannappel provides as an example.

Topology optimization or bionic structures help minimize material usage without compromising functionality. And last but not least, optimized designs can extend product life cycles.

Rudolf Franz, CEO of the Voxeljet AG

This gives designers the opportunity to move from "Design for Manufacturing" to "Design for Functionality." "This results in new, highly efficient products. Multiple parts can also be consolidated into a single component, reducing material and production effort," explains the CEO of Voxeljet. Lighter and more efficient components lead to savings in production resources and later use, e.g., through reduced energy consumption in moving parts. "Topology optimization or bionic structures contribute to minimizing material usage without compromising functionality. And finally, optimized designs can extend product life cycles," summarizes Rudolf Franz. Additionally, DfAM supports the concept of recyclability (Design for Recycling). "By considering the end of the component's life, manufacturers can facilitate disassembly and recycling, promote a circular economy, and reduce landfill waste," says Coblens from Stratasys.

Conclusion: Additive manufacturing offers a potentially transformative way to reshape how we produce, consume, and think about the lifecycle of our products. When applied correctly, it can minimize waste, optimize design for efficiency, and make the most of sustainable materials.