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Sustainability of Additive Manufacturing

Is AM more sustainable compared to traditional manufacturing?

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Additive Manufacturing is often labeled as a more sustainable manufacturing solution compared to traditional methods like milling or casting. However, the question of whether AM is truly more sustainable is still debated and depends on a variety of factors. In this blog post, we explore key insights on the sustainability of AM and its environmental impact.

What you will find in this section

AM technologies are not automatically the most sustainable

While Additive Manufacturing has gained attention for its potential sustainability benefits, it’s important to note that AM technologies are not inherently more sustainable than conventional manufacturing methods. When compared to near-net-shape technologies like milling or casting, AM may have a similar or even smaller CO2 footprint, depending on the application and production process.

The example on the right compares CO2 emissions for producing an aluminum component using Laser Powder Bed Fusion, Milling, and Sand Casting. The left bar represents production with a 60-micron layer thickness and a 400-watt laser, where CO2 emissions per part are higher than those of milling and sand casting. However, by using a 1 kW laser and a 90-micron layer, the printing time and CO2 footprint are significantly reduced. Despite this, sand casting remains the most environmentally friendly option.

Besides printing parameters, other factors such as production batch size, alloy group and the part design have a big influence on the CO2 emissions.

The Role of Regional Energy Mix in the CO2 Footprint

The regional energy mix where a part is produced has a large influence on its overall CO2 footprint, especially for metals like aluminum and steel alloys. AM processes powered by renewable energy sources, such as solar or wind, can significantly reduce the carbon impact. This makes local AM production, using renewable energy, a key strategy for improving sustainability in certain regions.

The most significant factor influencing the sustainability of AM, particularly for metals like titanium, is the energy used in the raw material production process. Using renewable energy in the production of materials has the largest impact on reducing the overall CO2 footprint. In addition, the development of new technologies that allow for the recycling of raw materials or the use of 100% recycled powder will further reduce the environmental impact of AM production.

The left comparison shows how the energy mix influences the CO2 footprint. Using “zero-emission” energy for LB-PBF (Laser Beam Powder Bed Fusion) can reduce the CO2 footprint of aluminum parts by nearly 50%. The primary factor influencing the CO2 footprint is the embedded energy in the raw material. The difference in CO2 emissions between LB-PBF and casting processes is primarily driven by the recycling rate in casting, compared to the support and powder waste generated in AM  processes.

In-Use Efficiency Savings Can Outweigh Production Emissions

While AM production itself can involve some carbon emissions, the in-use savings from weight or efficiency-optimized AM designs can far exceed these emissions. For example, lighter parts can improve fuel efficiency in transportation, and more efficient parts can lead to energy savings in manufacturing. These in-use benefits often have a larger environmental impact than the emissions generated during production, though the savings are highly dependent on the application.

How Weight-Optimized AM Designs Reduce CO2 Emissions

One of the significant sustainability advantages of AM lies in its ability to produce weight-optimized parts. These designs reduce the amount of raw material used, which in turn lowers the embedded CO2 emissions in the material. Moreover, because AM often requires less energy in the production process compared to traditional methods, the overall CO2 emissions from part production can be significantly reduced.

The example on the left illustrates the potential in-use savings of an aerospace aluminum bracket. The chart compares CO2 emissions from the conventional design, which are higher than those from the current milling process. This difference primarily results from greater CO2 emissions during powder production.

The right chart presents a theoretical calculation of in-use savings for a bracket with 50% reduced weight. For this example, it is assumed that each kilogram of weight saved equates to 2,500 liters of kerosene annually, and the aircraft’s lifetime is 20 years. While CO2 emissions from material production are already reduced, the most significant savings come from a 43-ton reduction in CO2 emissions over the aircraft’s lifetime. Although the exact values in this example may vary, it clearly demonstrates the substantial potential for in-use savings.

Conclusion: The Future of Sustainable AM

Additive Manufacturing holds great promise for a more sustainable future, but it is not a one-size-fits-all solution. The sustainability of AM depends on factors such as material optimization, energy sources, and production techniques. While AM offers significant environmental benefits, especially when used with renewable energy and optimized designs, it’s essential to consider each case individually to determine the overall environmental impact.

How to use AM in the most sustainable way? 

Determining whether Additive Manufacturing is more or less sustainable for a specific component can be challenging and may lead to detailed discussions. However, there are several ways designers can positively influence sustainability in AM:

  1. Part Identification: Focus on components where AM can significantly reduce the carbon footprint.
  2. Design Optimization: Redesign parts to maximize AM benefits, such as:
    • Lightweighting airplane components
    • Improving motor efficiency
    • Extending tool lifespan
  3. Repair: Consider using AM for component repairs to extend their lifespan and reduce waste.

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Sinter-based AM technologies and process chain

Sinter-based AM - a technology overview

Many different printing technologies - one sintering process

The sinter-based AM (SBAM) technologies have, as the name suggests, the sintering process in common. In this process, the printed green part is consolidated into a dense part and receives its final properties. The green part can be printed in advance using different technologies.They all have in common that metal powder is bound to the desired shape by a binder. The best-known printing technologies include Binder Jetting and Filament Material Extrusion.

In this section, you learn everything about the sinter-based AM  process chain and get an overview of the different printing technologies.

Goal and structure of this course

This course is aimed at engineers, designers and other professionals that are working closely with sinter-based AM technologies. The goal is to cover the most important aspects that will enable engineers and designers to fully grasp the capabilities and technical limitations of the printing technologies and the sintering process to succeed in technology selection and part design. Besides going through the course from the beginning until the end, this course can also act as a constant source of knowledge while working on AM projects. 

The course is structured into the following sections.

This section will start with an overview of the sinter-based AM process chain and its printing technologies, followed by a technology deep dive into the most important aspects of the BJT technology, followed by a closer look at the debinding and sintering step also including sintering simulation .

The second section will provide an overview of the different materials that are available as well as part characteristics that can be achieved with the BJT process and typical methods for quality assurance. Finally, several common defects in the BJT process are presented. 

The last section will act as a guideline for designers. Besides generally describing the process when designing for Additive Manufacturing, actionable restrictions and guidelines for the BJT process are provided. The final section will present several design examples from different industries. 

What you will find in this section

Sinter-based AM process chain

From digital model to finished part

Data preparation

Simulation to compensate the deformation during the sintering step, nesting of parts and definition of printing parameters

Printing

Through various printing processes, different feedstocks such as metal powders, filaments, pellets or dispersions are processed into green parts

Unpacking

Unpacking of fragile green parts needs to be done carefully and is typically a manual process.

Debinding

Debinding describes the process of removing the binder which results in a brown part

Sintering

To reach the structural integrity of a metal part, a sinter process is required. The powder particles fuse together to a coherent, solid structure via a mass transport that occurs at the atomic scale driven via diffusional forces.

The brown part shrinks ~13-21 % in each direction.

The process chain of sinter-based technologies differs from other AM Technologies. Especially the post-printing processes (debinding and sintering) are crucial to achieve the intended mechanical properties.

Technology principle

How does Binder Jetting work?

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Afterwards the build platform moves downward by the amount of one layer thickness and a new layer of powder is applied. Again, the liquid binder is deposited and hardened in the required regions of the next layer to form the green body. This process is repeated until the complete part is printed. After the complete printing process is finished the parts have to be removed from the “powder cake” meaning the surrounding loose but densified powder. To improve the removal of the excess powder from the green body often brushes or a blasting gun with air pressure are used.

To create a dense metal part the 3D printed green body has to be post-processed in a debinding and sintering process. Similar to the metal injection molding process BJT parts are placed in a high temperature furnace, where the binder is burnt out and the remaining metal particles are sintered together. The sintering results in densification of the 3D printed green body to a metal part with high densities of 97 % to 99,5%, dependent of the material.

Printing Technologies

Metal Binder Jetting

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Material Extrusion

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Mold Slurry Deposition

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Metal Selective Laser Sintering

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting