SUSTAINABILITY IN METALS ADDITIVE

MANUFACTURING
Seminar Report

Submitted in partial fulfillment of the requirements for the award of the

degree of

Bachelor of Technology

in

Metallurgical Engineering and Materials Science

by

MOHIT VERMA (Roll No. 200110068)

Department of Metallurgical Engineering and Materials Science

INDIAN INSTITUTE OF TECHNOLOGY BOMBAY
 CERTIFICATE

This seminar report titled “SUSTAINABILITY IN METALS ADDITIVE

MANUFACTURING ” by MOHIT VERMA (Roll No. 200110068) is approved for the
course MM 396.

Examiners

Supervisor

Date: 10th April, 2024

 DECLARATION

I declare that this written report submission titled " SUSTAINABILITY IN METALS
ADDITIVE MANUFACTURING " contains my own words, and that I have adequately
credited and referenced the original sources when others' ideas or words have been
incorporated. I further declare that I have followed all academic honesty and integrity rules in
my submission and have not misrepresented or faked any idea, data, fact, or source. I
understand that any violation of the foregoing will result in disciplinary action by the
institute, as well as legal action from the sources who were not correctly referenced or from
whose sufficient permission was not obtained when required.

MOHIT VERMA (Roll No. 200110068)

Date: 10th April, 2024

 ACKNOWLEDGEMENT

I would like to express my gratitude to Prof. A. Durga, my seminar guide, for his guidance
with inputs and recommendations, as well as for presenting me with a fascinating topic to
work on.

MOHIT VERMA (Roll No. 200110068)

Date: 10th April, 2024

 ABSTRACT

Metal powder additive manufacturing (AM), often referred to as 3D printing, has emerged as
a transformative technology with the potential to reshape manufacturing processes. While
lauded for its ability to reduce waste, concerns about the environmental impact of metal AM
necessitate a critical examination of its sustainability. This literature review delves deeper into
the current understanding of metal AM's sustainability compared to traditional methods. It
explores the potential benefits of AM in terms of material usage, lightweight design, and on-
demand production. Additionally, the review addresses sustainability challenges associated
with powder production, energy consumption, and waste management. Strategies for
improving the sustainability of metal AM, including powder reuse and recycling, closed-loop
systems, and energy-efficient processes, are discussed. The crucial role of Life Cycle
Assessment (LCA) and Design for Additive Manufacturing (DfAM) in optimizing the
environmental impact of metal AM is also highlighted. Finally, the report identifies key areas
for future research and emphasizes the need for ongoing efforts to ensure the environmentally
responsible use of this promising technology.
 CONTENTS

1 Introduction 1

2 Traditional Manufacturing vs. Metal Powdered AM: A Sustainability

Comparison 2

3 Sustainability Challenges in Metal Powdered AM 4

3.1 Metal Powder Production: Energy Intensity and Environmental Impacts 4
3.2 Health and Safety Concerns of Metal Powders 4
3.3 Energy Consumption of the AM Process 5
3.4 Waste Management Challenges 5

4 Strategies for Sustainable Metal Powdered AM 7

4.1 Powder Reuse and Recycling 8
4.2 Recycled Metal Sources for Powder Production 9
4.3 Energy-Efficient AM Systems and Processes 9

5 Life Cycle Assessment and Design for Additive Manufacturing 10

5.1 Life Cycle Assessment (LCA): A Holistic Approach to Sustainability 10
5.2 LCA: Comparing Metal Powdered AM with Traditional Methods 11
5.3 Design for Additive Manufacturing (DfAM) plays a critical role in LCA 12

6 Future Directions and Research Needs 13

6.1 Advancements in Powder Production 13
6.2. Efficient AM Systems and Processes 13
6.3 Improved Recycling Methods for Powders and Materials 14
6.4 Standardization and Regulations 14

7 Conclusion 16

References 18
 CHAPTER 1

INTRODUCTION
Metal powder AM utilizes a computer-controlled process to build objects layer-by-layer from
metal powder. This technology offers significant advantages in terms of design flexibility,
enabling the creation of complex geometries and intricate internal structures that would be
impossible with traditional subtractive methods like machining. Additionally, AM allows for
on-demand production, minimizing material stockpiling and facilitating the production of low-
volume, customized parts. As AM adoption grows across various industries, including
aerospace, automotive, and medical, sustainability considerations are becoming increasingly
crucial. Sustainable AM strives to minimize environmental impact throughout the entire
product life cycle, encompassing raw material extraction, processing, production, use, and end-
of-life disposal. This critical literature review aims to analyze the current understanding of the
sustainability of metal powdered AM, identifying both its potential benefits and remaining
challenges.

[Fig - Schematic illustration of the Electron Beam Melting (EBM)-based AM technology]

1
 CHAPTER 2

Traditional Manufacturing vs. Metal Powdered AM: A Sustainability

Comparison

Traditional metal manufacturing processes, such as machining, casting, and forging, often
involve significant material waste due to subtractive techniques. Studies suggest that scrap
metal from these methods can exceed 50% of the initial material [Ref 3]. In contrast, metal
powdered AM boasts the potential for material utilization rates exceeding 90%, drastically
reducing waste generation [Ref 1]. This translates to a lower environmental footprint associated
with raw material extraction, processing, and transportation. For instance, a study by [Ref 1]
found that AM could achieve a 70% reduction in material usage compared to conventional
machining for a specific aerospace component.

[Fig - Comparing material waste generation between traditional subtractive methods (e.g.,
machining) and metal AM.]

Furthermore, metal AM allows for the design and production of lightweight components.
Lighter parts in applications like airplanes and automobiles can contribute to reduced fuel
consumption and emissions throughout the product's life cycle [Ref 2]. For example, research
suggests that weight reduction through AM in the automotive industry can lead to fuel
efficiency improvements of up to 15% [Ref 10]. Additionally, AM offers the freedom to create
intricate internal structures that optimize strength-to-weight ratio, further facilitating weight
reduction.

2
However, it is important to acknowledge limitations in this comparison. The environmental
impact of traditional methods can vary depending on the complexity of the part, the specific
manufacturing techniques employed, and the efficiency of the processes. Additionally, a
comprehensive LCA is necessary to fully understand the environmental impact of both AM
and traditional methods for a specific application.

[Fig - An image of a lightweight AM-produced component for an airplane]

3
 CHAPTER 3

Sustainability Challenges in Metal Powdered AM

Despite its potential benefits, metal powdered AM faces several sustainability challenges that
require ongoing attention. Here's a deeper dive into these challenges:

3.1. Metal Powder Production: Energy Intensity and Environmental Impacts

 Energy Consumption: The production of metal powders for AM often involves

atomization techniques like gas or water atomization. These processes require
significant energy to create the high temperatures and pressures needed to melt and
atomize the metal. Studies suggest that atomization can account for a substantial portion
of the total energy consumption within the AM life cycle [Ref 11].
 Environmental Consequences of Mining: Raw materials for metal powders are
extracted through mining activities, which can have various environmental
consequences. These include habitat destruction, air and water pollution from dust and
emissions, and potential for land degradation. Additionally, mining some rare earth
elements used in high-performance AM alloys can be particularly harmful [Ref 6].

3.2. Health and Safety Concerns of Metal Powders

Metal powders pose health risks due to their fine size and potential reactivity. Here's a
breakdown of the specific concerns:

 Respiratory Issues: Inhalation of fine metal powder particles can lead to respiratory
problems such as metal fume fever, lung inflammation, and even fibrosis. The severity
of these issues depends on the specific metal, particle size, and exposure levels [Ref
12].
 Skin Irritation and Allergies: Skin contact with metal powders can cause irritation,
dermatitis, or allergic reactions. Proper personal protective equipment (PPE) is crucial
for workers handling metal powders.

4
 [Fig - An SEM image of metal powder particles to illustrate their fine size]

3.3. Energy Consumption of the AM Process

The AM process itself can be energy-intensive, particularly techniques like Laser Powder Bed
Fusion (LPBF) which utilize high-powered lasers to melt metal powder layer-by-layer. While
some energy savings can be achieved through process optimization (e.g., reducing laser power
or scan speed), the overall environmental impact depends heavily on the energy source used:

 Dependence on Fossil Fuels: If the electricity powering the AM equipment comes

from fossil fuels, it contributes to greenhouse gas emissions and air pollution. This
negates some of the potential environmental benefits of AM.

3.4. Waste Management Challenges

Even though AM boasts reduced material waste compared to traditional methods, there are still
waste management considerations:

 Unutilized Metal Powder: Not all the metal powder used in the AM process gets
deposited into the final part. Unutilized powder requires proper handling and
management to prevent environmental contamination. Improper disposal can lead to
heavy metals leaching into soil and water, posing risks to human health and ecosystems
[Ref 5].
 Support Structures: Many AM processes require support structures to hold parts
during printing. These support structures are typically removed after printing and
contribute to the overall waste stream.

5
 [Fig - 3D printing support structure]

 Post-Processing Waste: Finishing operations like machining and surface treatments

can generate waste materials that require proper disposal or recycling.

6
 CHAPTER 4

Strategies for Sustainable Metal Powdered AM

Research efforts are actively exploring avenues to improve the sustainability of metal
powdered AM. Here's a deeper dive into some promising strategies:

4.1. Powder Reuse and Recycling

Unutilized metal powder from AM processes represents a significant opportunity for resource
recovery and waste minimization. Here are some key techniques for powder reuse and
recycling:

 Mechanical Separation and Sieving: After printing, techniques like sieving and
sifting can separate unutilized powder particles from other debris like support structures
or spatter. The recovered powder can then be assessed for size distribution, chemical
composition, and flowability. Particles meeting the required specifications can be
reintroduced back into the AM process, reducing virgin material usage and waste
generation [Ref 8].
 Powder Re-atomization: In some cases, recovered powder particles may not be
suitable for direct reuse due to factors like size variation, contamination, or
oxidation. Re-atomization techniques can be employed to remelt the powder and create
new, high-quality powder particles that meet the specifications for the AM process.
However, re-atomization adds an additional energy step to the powder life cycle, and
its environmental impact needs careful consideration.
 Closed-Loop Systems: Developing closed-loop systems for powder management is a
promising approach for maximizing resource utilization and minimizing waste. These
systems aim to capture, clean, and reuse metal powder within a controlled AM
production environment. They can incorporate various techniques like sieving,
filtration, and potentially even in-situ re-atomization to ensure the quality and
consistency of the recycled powder for reuse in subsequent printing jobs [Ref 14].

7
[Fig - A flowchart illustrating the concept of a closed-loop system for powder management in
AM.]

4.2. Recycled Metal Sources for Powder Production

Transitioning to recycled or secondary metal sources for powder production offers significant
potential to reduce the environmental impact of metal AM. Here's a breakdown of the benefits
and considerations:

 Reduced Environmental Impact: Utilizing recycled metals for powder production

minimizes the environmental burden associated with virgin material extraction and
mining activities. This includes reducing energy consumption, air and water pollution,
and habitat destruction.
 Economic Benefits: Recycled metal feedstock can be a more cost-effective alternative
to virgin materials, especially for high-value metals.

8
  Challenges and Considerations: The quality and consistency of recycled metals can
vary depending on the source and processing methods. Strict quality control measures
are crucial to ensure the suitability of recycled materials for high-performance AM
applications. Additionally, some impurities present in recycled metals may require
additional processing steps before powder production. Research in this area is crucial
for developing efficient and cost-effective methods for utilizing recycled metals in AM
powder production [Ref 9].

4.3. Energy-Efficient AM Systems and Processes

Energy consumption associated with the AM process itself is another key area for
sustainability improvements. Here are some strategies being explored:

 Process Optimization: Optimizing process parameters like laser power, scan speed,
scan path, and build plate temperature can significantly reduce energy consumption
during metal AM processes. Advanced software tools and simulation techniques can
aid in identifying optimal process settings for specific applications.
 Alternative Energy Sources: Powering AM equipment with renewable energy
sources like solar or wind power is crucial for ensuring truly sustainable AM
practices. Transitioning away from electricity generated by fossil fuels minimizes
greenhouse gas emissions and air pollution associated with the AM process.
 Novel AM Technologies: Research into emerging AM technologies like cold spray or
binder jetting holds promise for lower energy consumption compared to traditional
methods like Laser Powder Bed Fusion (LPBF). Cold spray utilizes a high-velocity gas
stream to accelerate metal powder particles onto a substrate, achieving bonding without
melting the powder. Binder jetting employs a liquid binder to selectively adhere metal
powder particles together, potentially offering lower energy requirements compared to
LPBF. However, these technologies are still under development, and their broader
adoption will depend on further advancements in material compatibility, process
control, and mechanical properties of printed parts [Ref 15, 16].

By implementing these strategies, researchers and industry leaders can significantly improve
the sustainability profile of metal powdered AM, paving the way for a more environmentally
responsible manufacturing future.

9
 CHAPTER 5

Life Cycle Assessment and Design for Additive Manufacturing

5.1. Life Cycle Assessment (LCA): A Holistic Approach to Sustainability

Life Cycle Assessment (LCA) is a standardized framework for evaluating the environmental
impact of a product or service throughout its entire lifespan. This cradle-to-grave approach
considers all stages, encompassing:

 Raw Material Extraction and Processing: The environmental burdens associated

with mining or sourcing raw materials, including energy consumption, air and water
pollution, and potential land degradation. For metal powdered AM, this stage includes
the environmental impact of metal extraction and the processes involved in powder
production (e.g., atomization).
 Manufacturing: The environmental impact of the manufacturing process itself,
including energy consumption, waste generation (both material waste and emissions),
and the use of auxiliary materials like coolants or lubricants. In AM, this stage considers
the energy consumption of the AM process, powder handling, and wastewater treatment
from post-processing operations.
 Use: The environmental impact of the product during its functional lifespan. For
example, for a lightweight aircraft component manufactured using AM, this stage
would consider the reduction in fuel consumption and emissions achieved due to the
lighter weight.
 End-of-Life: The environmental impact associated with the product at the end of its
useful life. This could include recycling, reuse, or disposal options, and their
corresponding environmental burdens.

By conducting a comprehensive LCA, manufacturers and designers can gain a holistic

understanding of the environmental footprint of a product throughout its life cycle. This allows
for the identification of areas for improvement and the development of more sustainable
manufacturing practices.

10
 [Fig - Different stages of a product's life cycle (cradle-to-grave approach)]

5.2. LCA: Comparing Metal Powdered AM with Traditional Methods

LCA plays a crucial role in objectively comparing the sustainability of metal powdered AM
with traditional manufacturing methods for specific applications. Here's a breakdown of the
key considerations:

 Material Usage: Metal AM often boasts a significant advantage in terms of material

utilization. Reduced waste generation due to near-net-shape manufacturing and the
ability to design complex lightweight structures contribute to a potentially lower
environmental impact compared to subtractive methods like machining.
 Energy Consumption: The energy intensity of the AM process itself, particularly
techniques like LPBF, can be a concern. LCA studies need to factor in the energy source
used (fossil fuels vs. renewables) to determine the overall environmental impact.
Additionally, energy consumption associated with powder production needs to be
considered.
 Other Factors: The complexity of the part, the specific materials used, and the chosen
end-of-life options (e.g., recycling) all influence the overall environmental impact. A
comprehensive LCA should account for these factors to provide an accurate
comparison.

An illustrative example: A study by [Ref 7] compared the LCA of an aerospace component

manufactured using both AM and traditional machining. The study found that AM resulted in
a substantial reduction in material waste. However, the energy consumption of the AM process
partially offset the material savings. This highlights the importance of considering all aspects
within an LCA to make informed decisions.

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5.3. Design for Additive Manufacturing (DfAM) plays a critical role in LCA

By incorporating DfAM principles, designers can significantly influence the environmental

impact of metal powdered AM as reflected in LCA studies. Here's how DfAM contributes to
a more sustainable life cycle:

 Reduced Material Usage: Strategies like internal lattice structures, topology

optimization, and part consolidation can minimize material requirements, leading to
lower environmental burdens throughout the life cycle, from material extraction to
waste disposal.
 Lower Energy Consumption: DfAM principles that promote reduced support
structures and optimized wall thickness can contribute to a shorter printing time and
lower energy consumption during the AM process.
 Improved End-of-Life Options: DfAM can influence the ease of disassembly and
recyclability of AM-printed parts. Designing for disassembly allows for easier
separation of materials and facilitates recycling at the end of life, further reducing
environmental impact.

The conclusion is that LCA provides a valuable tool for objectively assessing the
environmental impact of metal powdered AM compared to traditional methods. By
incorporating DfAM principles, designers can create parts with a minimized environmental
footprint throughout their life cycle, paving the way for a more sustainable future for metal AM.

12
 CHAPTER 6

Future Directions and Research Needs

Despite ongoing advancements, significant research efforts are still required to address
remaining sustainability challenges in metal powdered AM. Here's a deeper look at key areas
for exploration:

6.1. Advancements in Powder Production

 Energy-Efficient Powder Production Methods: Research is crucial for developing

more energy-efficient techniques for metal powder production. This could involve
exploring alternative atomization methods with lower energy requirements or utilizing
renewable energy sources to power the atomization process.
 Alternative Feedstocks for Powder Production: Transitioning towards recycled
metal sources for powder production offers significant potential for environmental
benefits. Research efforts should focus on developing cost-effective methods for
cleaning, purifying, and processing recycled metals to meet the stringent quality
requirements for AM powders. Additionally, exploring the feasibility of using
alternative materials like metal alloys or composites with lower environmental impact
during extraction and processing is an interesting avenue.

6.2. Efficient AM Systems and Processes

 Optimization of Existing Technologies: Continued research on optimizing existing

AM technologies like LPBF can lead to significant improvements in energy efficiency.
This includes advancements in areas like laser control systems, scan path optimization,
and process parameters to minimize energy consumption per unit of material deposited.
 Novel AM Technologies: Exploring emerging AM technologies with potentially lower
energy footprints compared to traditional methods holds promise for the future of
sustainable AM. Here are some key areas of interest:
o Cold Spray: This method utilizes a high-velocity gas stream to accelerate metal
powder particles onto a substrate, achieving bonding at a lower temperature
compared to melting. While still under development, cold spray offers potential
for lower energy consumption and the ability to process some materials that are
difficult to melt using traditional AM methods.

13
 o Binder Jetting: This technique employs a liquid binder to selectively adhere
metal powder particles together, potentially offering lower energy requirements
compared to LPBF. However, further research is needed to improve the
mechanical properties and post-processing requirements for binder jetted parts.

6.3. Improved Recycling Methods for Powders and Materials

Developing cost-effective and efficient methods for powder reuse and recycling is crucial for
minimizing waste generation and maximizing resource utilization in metal AM. Here are some
key areas of focus:

 Powder Separation and Cleaning Techniques: Improved techniques for separating

unutilized powder from support structures and other debris are essential. Additionally,
methods for cleaning and decontaminating recycled powder to ensure its suitability for
reuse need further development.
 Closed-Loop Powder Recycling Systems: Research efforts should focus on
developing robust and cost-effective closed-loop powder recycling systems specifically
designed for metal AM. These systems would capture, clean, and potentially re-atomize
unutilized powder within the AM production environment, minimizing waste and
maximizing resource utilization.
 Recycling of AM Parts: Developing commercially viable methods for recycling AM
parts at the end of their lifespan is an important area for future research. This could
involve mechanical or chemical processing techniques to recover metal powder or
valuable materials from used AM parts.

6.4. Standardization and Regulations

Standardization and regulations are crucial for promoting sustainable practices throughout the
metal AM industry. Here's a breakdown of key needs:

 Standardization for Sustainable AM Practices: Developing industry-wide standards

for sustainable AM practices would provide a framework for responsible powder
handling, energy efficiency, and waste management. This could include guidelines for
powder recycling, energy consumption benchmarks, and best practices for DfAM to
minimize material usage.
 Regulations for Powder Handling and Disposal: Regulations are needed to ensure
responsible handling and disposal of metal powders to minimize environmental risks
associated with potential heavy metal contamination. This could involve regulations on
worker safety protocols, airborne emission control during AM processes, and proper
disposal procedures for waste powder.

14
By addressing these future directions and research needs, the metal powdered AM industry can
move towards a more sustainable future. Continuous advancements in powder production,
energy-efficient AM technologies, improved recycling methods, and the establishment
of standardization and regulations will be crucial for ensuring the long-term
environmental responsibility and economic viability of this transformative manufacturing
technology.

[Fig - Schematic illustration of a cold spray system or binder jetting AM technology

representing advancements in energy-efficient processes.]

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 CHAPTER 7

CONCLUSION

This critical literature review has provided a comprehensive analysis of the current
understanding surrounding the sustainability of metal powder additive manufacturing (AM).
While AM boasts promising potential for a more sustainable manufacturing future through
design flexibility and reduced material waste, significant challenges related to energy
consumption, powder production processes, and waste management require ongoing attention.

Key Takeaways:

 Material Utilization and Design: Metal AM offers a significant advantage in terms of

material utilization, often exceeding 90%, compared to subtractive methods with
substantial scrap generation. Additionally, AM allows for the design and production of
lightweight parts, leading to potential reductions in fuel consumption and emissions
throughout a product's life cycle.
 Sustainability Challenges: Despite these advantages, AM also faces sustainability
hurdles. Energy-intensive processes like powder production and AM operations
themselves contribute to the environmental footprint. Metal powder handling and waste
management practices also require careful consideration to minimize environmental
risks.
 Life Cycle Assessment (LCA) and Design for Additive Manufacturing (DfAM):
LCA is a valuable tool for objectively comparing the environmental impact of AM with
traditional methods for specific applications. DfAM principles play a crucial role in
optimizing part design for sustainability, leading to reduced material usage, lower
energy consumption during printing, and improved end-of-life options through
designing for disassembly and recyclability.

The Road to a Sustainable Future for Metal Powdered AM:

 Future Research and Development: Continued research efforts are crucial for
addressing remaining sustainability challenges. This includes exploring advancements
in powder production with a focus on energy efficiency and alternative feedstocks like
recycled metals. Additionally, developing more efficient AM systems and processes,
including novel technologies like cold spray and binder jetting, holds promise for lower
energy consumption. Efforts to improve powder reuse and recycling methods, including
closed-loop systems and recycling of AM parts at end-of-life, are vital for minimizing
waste generation and maximizing resource utilization.
 Standardization and Regulations: Industry-wide standards for sustainable AM
practices are essential for promoting responsible powder handling, energy efficiency,
and waste management. Standardization efforts could encompass guidelines for powder
recycling, energy consumption benchmarks, and best practices for DfAM.
Additionally, regulations for powder handling and disposal are necessary to minimize
environmental risks associated with heavy metal contamination.

16
By addressing these outlined areas for future research and development, coupled with industry
collaboration and the establishment of standardization and regulations, the metal powdered
AM industry can pave the way for a more sustainable future. Continuous advancements will
ensure the long-term environmental responsibility and economic viability of this
transformative manufacturing technology.

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