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Manufacturing
IS 3D PRINTING THE SUSTAINABLE MANUFACTURING SOLUTION?
Carolyn Schwaar
Contributor
Opinions expressed by Forbes Contributors are their own.
I'm a journalist covering professional and industrial 3D printing.
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The world’s largest jet engine, the GE9X developed by GE Aviation, has six
different kinds of ... [+] 3D-printed parts inside (more than 300 individual
3D-printed parts) and boasts 12% lower fuel consumption and 10% lower operating
costs than competing engines.
Boeing
3D printing, or additive manufacturing (AM) as it is called in industrial
applications, is gaining a foothold in factories and shop floors across the
country. Compared to traditional manufacturing, it can be faster, cheaper, and
more flexible, but how sustainable is it? Can it help companies like GE,
Siemens, and Volkswagen — companies that have both adopted AM and pledged to
lower their carbon footprint — achieve their sustainability goals?
A new tool out this week from Ampower, an EU-based additive manufacturing think
tank and consultancy, is designed to help companies measure the energy
consumption and CO2 emission of metal 3D printing.
The company’s new Sustainability Calculator is a tool for manufacturers to input
and compare various metal material choices and AM technology combinations to
determine the resulting CO2 emissions. Customization options and overrides can
account for choices made throughout a globally distributed process chain.
“There is no general answer to which manufacturing technology has the lowest
carbon footprint,” Ampower says in its new report Sustainability of Metal
Additive Manufacturing, since the overall footprint is heavily influenced by the
type of metal and the part geometry. However, in comparing two like parts: 1,000
brackets designed to be milled vs. 1,000 similar brackets designed to be 3D
printed, the calculator found that sand casting had the lowest CO2 emissions
when the parts are made in aluminum. But change the material, and the equation
shifts. The same brackets traditionally milled in titanium result in CO2 levels
twice as high as AM technologies, such as laser powder bed fusion and binder
jetting.
Comparing sustainability of AM and traditional manufacturing doesn’t end when
the part is manufactured, many in the 3D printing industry argue. There’s a
knock-on effect with additive manufactured parts that enables conservation far
down the value chain. Consider the brackets mentioned above, which are used for
aerospace applications.
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With aircraft parts, the weight is often linked directly to fuel consumption
and, therefore, CO2 emissions. 3D printing technology can create shapes not
possible with other technology enabling parts that use less material and weigh
less but are equal in strength. AMpower’s example bracket designed for AM
pictured below uses less material than the conventionally manufactured version.
A comparison of aerospace brackets designed for milling (left) and additive
manufacturing (right) ... [+] shows in-use CO2 savings for the additively
manufactured version.
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“We hope that companies will use the tool to optimize their processes and parts
toward low carbon footprint,” says Matthias Schmidt-Lehr, Ampower’s managing
partner. “Also, it should bring clarity regarding the question, where additive
manufacturing can contribute to a lower footprint, and where traditional
technologies are more efficient.”
According to Ampower, a 1-kg weight saving in a plane translates to an annual
savings of 2,500 liters of kerosine, and, assuming a 20-year lifespan of an
aircraft, this results in savings of up to 126,000 kg of CO2. “Similar savings
can be made for many other applications, such as engines, pumps or turbines,
where weight reduction or performance increase have a large impact on in-use
emission,” says Schmidt-Lehr.
When assessing additive manufacturing as a sustainable win for manufacturing,
it’s here, in the end-use applications, where the technology can really shine.
“In-use savings of weight or efficiency optimized AM designs can be multitudes
larger than the emission from part production itself,” Ampower says in its
latest report. “However, in-use savings, if any exist, are strongly dependent on
the application.”
In addition to their lighter weight design and part consolidation, which
increases efficiency, the fact that most additively manufactured parts are
produced locally, eliminating shipping and the associated emissions, is another
datapoint in AM’s favor. There’s also the emerging practice of keeping
spare-part inventories in digital format ready to be 3D printed on-demand as
needed, instead of as physical parts sitting in warehouses.
Looking forward, Ampower says increasing recycling rates in raw material
production and new metal powder production technologies from 100% recycled
material will have a significant impact on reducing 3D printing’s CO2 footprint
even further.
Follow me on Twitter or LinkedIn.
Carolyn Schwaar
I'm a journalist with 25+ years' experience covering business, technology, and
additive manufacturing. I'm also an editor at All3DP magazine.
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