MAM Week-11

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PT
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Dr. Amandeep Singh
Imagineering Laboratory
IIT Kanpur
▪ Introduction to Sustainability
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▪ Sustainable impact evaluation
▪ Sustainable design approaches
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▪ Lean & Green Business Model
▪ Design quality and sustainability
▪ Sustainable design methodology for AM
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▪ Design guidelines and design rules
▪ AM and sustainability in industry
1. The concept of needs, in particular the essential needs
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of the world’s poor, to whom overriding priority should be
given.
2. The idea of limitations imposed by the state of
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technology and social organization on the environment’s
ability to meet present and future needs
N
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PT
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Growth of additive manufacturing
Wohlers Report (2013) Additive manufacturing and 3D printing state of the industry annual worldwide progress report. ISBN 0-9754429-9-6
▪ Sustainability enables humans and nature to live in a way that
meets the social, economic, and other requirements of present
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and future generations.
▪ It is critical to apply eco-design principles and develop
▪ Additive PT
greener products and production processes
manufacturing has the capability of producing
components with the lowest amount of raw material.
N
EL
PT
N
Source:
https://www.frontiersin.org
▪ Additive manufacturing is an
innovative and environmentally
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friendly approach to make
parts.
less
PT
▪ Consumes less resources and
has emissions
conventional machining.
than
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Rogers, Peter P., Kazi F. Jalal, and John A. Boyd. An introduction to sustainable development. Routledge, 2012.
▪ Supply chain efficiency and raw material reduction.
EL
▪ Reduced need to mine and process natural ores.
▪ Replacing energy-inefficient and wasteful manufacturing
techniques like casting or CNC machining that uses cutting
fluids.
PT
N
Source:
▪ Ability to design more efficient goods by adding conformal
cooling, heating, and gas flow routes, etc.
EL
▪ Carbon footprint reduction
▪ Lighter parts in aircraft boost fuel efficiency and minimize
carbon emissions.
PT
N
Source:
Additive manufacturing also presents some sustainability
disadvantages.
EL
▪ Some techniques require support structures that are removed after
each part is made
▪ AM machines need a controlled environment without excessive
PT
heat and humidity for both machine and raw material
▪ Some machines require pre-heated and air-controlled building
chambers
N
▪ Some machines also require energy for processing raw materials,
such as lasers.
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PT
N
Source:
Eco-design
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▪ Eco-design incorporates
environmental considerations
into products to reduce their
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environmental impact.
▪ Eco-design displays itself in
real-world applications using
low-impact materials throughout
N
the manufacture.
Source:
http://www.oree.org/en/eco-design-platform.html
▪ Sustainable design includes economic imperatives, ethics, and
other socioeconomic sustainability factors
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▪ Applies ecological principles as design approaches, striving
for ‘triple bottom-line’ solutions.
PT
N
Source:
https://www.bth.se/eng
1. Cyclic: Organic, recyclable, compostable materials should
be used
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2. Solar: Solar or renewable energy should be used during
manufacture and product use.
3.
4.
ecosystems. PT
Safe: Manufacture, usage, and disposal should not harm
Efficient: The product should consume 90% less material,

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energy, and water than a 1990s equivalent.
5. Social: The manufacture and use of a product should not
impact on basic human rights or natural justice.
EL
PT
N
Source:
https://www.biothinking.com/btintro.htm
▪ The Sustainability Principles include a stronger notion of social
sustainability.
▪ In a sustainable society, nature is not subject to systematically
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increasing:
▪ Concentrations of substances extracted from the Earth’s crust
▪ Concentrations of substances produced by society
PT
▪ Degradation by physical means
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L & GBM
Operations
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Lean Green
Sustainability
PT
N
EL
PT
N
Source:
Pampanelli, A.B., Found, P. and Bernardes, A.M., 2015. Sustainable manufacturing: The lean and green business model. In Sustainable operations management (pp. 131-161). Springer
1. Define
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2. Identify
3. Make
4.
5.
Let
Pursue PT
N
L&GBM MODEL PRINCIPLES
1. Identify a stable value stream
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(VS)
2. Identify the environmental
impact (E)
PT 3. Measure the environmental

value streams (EVS)
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4. Improve the environmental
value streams (EVS)
5. Continuous Improvement
(CI)
Source:
Pampanelli, A.B., Found, P. and Bernardes, A.M., 2015. Sustainable manufacturing: The lean and green business model. In Sustainable operations management (pp. 131-161). Springer
▪ It is aligned to business strategy (environment is key)
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▪ It recreates the concept of cleaner production
▪ It improves the use of resources
PT
▪ It is an alternative for pollution prevention
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▪ It needs management support
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▪ It needs resources
▪ It needs implementers
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▪ It needs experts to direct and guide
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LEAN AND GREEN MODEL BENEFITS
▪ Education on Lean tools
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▪ Standardize process for production
▪ Team building from event
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▪ Roll out to other sites
▪ Ease Capital approval using
▪ Lean and Green
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▪ Implementation process—time
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▪ Impact on quality/throughput
▪ Capital expenditure required
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▪ Time and resources
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MASS AND ENERGY FLOW ANALYSIS
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PT
N
▪ Circular Economy is a sustainable growth paradigm that strives
to revolutionise how societies create, manufacture, and
consume goods and services.
EL
▪ Emerging technologies are transforming global value chains.
AI/ML, robotics, IoT, bioelectrochemical engineering, sharing
platforms, etc. play a crucial role in enabling circular business
models.
PT
N
Source:
worldbank.org/content/circular-economy-and-emerging-technologies
▪ Circular Economy business models enhance sustainability by:
▪ increasing efficiencies and reducing waste;
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▪ driving innovation by allowing new entrants in the markets
▪ increasing information transparency across companies
▪ enabling to shun the traditional materials
PT
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Source:
worldbank.org/content/circular-economy-and-emerging-technologies
The five circular business models are:
▪ Circular Supplies
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▪ Resource Recovery
▪ Product Life Extension
▪ Sharing Platform
PT
▪ Product as a Service
N
▪ Design quality affects a product's longevity from a sustainable
product perspective
EL
▪ A highly desirable object have long life and less negative
impact on the environment
PT
▪ A well-designed object is more sustainable and have more
value
N
▪ Additive manufacturing of a titanium bottle opener saved 90%
of the material compared to CNC machining because of the
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component's intricacy.
▪ It was made of titanium 64 utilizing selective laser melting to
remove as much material as feasible while keeping
mechanical properties.
PT
N
Additively manufactured titanium bottle opener
S.S. Muthu and M.M. Savalani (eds.), Handbook of Sustainability in Additive Manufacturing, Environmental Footprints and Eco-design of Products and Processes
▪ AM provides quantifiable sustainability benefits. Material use is
one.
EL
▪ After a simple sieving operation, most unmelted powder from
metal AM can be reused
PT
▪ Compared to normal manufacturing, waste is minimal
N
General Design Flow
EL
The whole design workflow can be divided into four stages
1. Functional design
2. Design optimization
PT
3. Design refinement
4. Environmental impact evaluation
N
N
PT
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▪ A functional specification drives this design stage
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▪ Functional specifications define a product's overall functions
and input/output qualities
▪ Designers can summarize the interaction between developed
PT
items and external agents based on the functional specification
▪ A generic black box model can be used to represent the input
functional specification
N
▪ Physical entities can be optimized to reduce environmental
impact and improve product performance
EL
▪ Multiscale AM-enabled design optimization methods consider
the environmental impact model's pre-feedback
PT
N
EL
PT
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General workflow of optimization process
S.S. Muthu and M.M. Savalani (eds.), Handbook of Sustainability in Additive Manufacturing, Environmental Footprints and Eco-design of Products and Processes
▪ A design refinement procedure is needed to modify some
optimized product design details due to the second design
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stage's coarse or irregular boundaries
▪ Material is eliminated where relative density is below the
threshold
PT
N
This general flow can be
divided into three main steps
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▪ Energy and material
consumption analysis
PT
▪ Life Cycle Inventory
▪ Life Cycle Impact Analysis
compilation
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Source:
https://ecochain.com
▪ LCIA provides additional information to assess life cycle inventory
(LCI) results.
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▪ It help users better understand the environmental significance of
natural resource use and environmental releases
PT
N
▪ Use the advantages that are included in RM processes
▪ Do not build the same parts designed for conventional manufacturing
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processes
▪ Do not consider traditional mechanical design principles
PT
▪ Reduce the number of parts in the assembly by intelligent integration
of functions
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The four stages of the product life cycle:
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1. Product and process design
2. Material input processing
3. Make-to-order component and product manufacturing
PT
4. Closing the loop
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Source:
https://www.business-to-you.com/product-life-cycle
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PT
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Ford, Simon, and Mélanie Despeisse. "Additive manufacturing and sustainability: an exploratory study of the advantages and challenges." Journal of cleaner Production 137 (2016): 1573-1587.
▪ Material and energy savings in the production of high value
products
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▪ Improved product functionality and efficiency in use
▪ Lower energy intensity and waste avoidance in the manufacturing
process
PT
N
Challenges:
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▪ Educating manufacturers about the potential uses and benefits
of AM
▪ Implementation of distributed maintenance system
PT
▪ Certification of new components
▪ Capturing and replicating learning in future applications
N
▪ Limited and uncertain performance due to low maturity of the
technology for large-scale structures
▪ Requirement for standards and regulations
Material input processing:
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▪ Process reactants are non-toxic and can be recycled locally
▪ Localised material recycling
PT
▪ Input recycled materials are from larger-scale recycling
systems, potentially more efficient than local recycling systems
▪ Diversion of by-product from waste stream
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Source:
https://ecochain.com
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▪ Material and process standardization
▪ Process scale-up for new materials
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▪ Possibility of material contamination
▪ Limited material options
▪ Limited recyclability of product at its end-of-life due to mixed
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materials
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PT
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Manufacturing:
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▪ Increased access to digital designs for spare parts
▪ More localised manufacturing
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▪ Less high-value waste generated
▪ Raised awareness of manufacturing process and its impacts
▪ Improved access to equipment
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▪ Increased equipment utilization
▪ More localized production through proximity of producer to
customer
Manufacturing:
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PT
N
Challenges at manufacturing stage:
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▪ Limited availability of digital designs
▪ Cost of acquiring new digital designs
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▪ Limited functionality and utility
▪ Reliability and quality of 3D printing process
▪ Encourages materialistic society and consumerism
N
▪ Services are currently fragmented and unevenly distributed
▪ Majority of services are lower-end consumer 3D printers
End-of-life strategies:
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▪ Small and simple equipment, quick and easy to use as mobile
or small-scale recycling station
▪ In-situ recycling of common waste from everyday products and
packaging
PT
▪ Improved product utilization
▪ Reduced material consumption
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▪ Designed for longevity
▪ Automated processes, all process steps integrated into one
▪ Remanufacturing and repair of high value components at low
cost
Challenges:
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▪ Limits on recyclability of material due to quality loss
▪ Educating consumers about recycling 3D printed material
PT
▪ Replication of business model to other sectors
▪ Limited integration of AM with other techniques in design and
production
N
▪ Required mindset shift for designers and engineers
▪ How do we measure sustainable impact evaluation?
▪ Explain the sustainable design approach.
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▪ Differentiate between Lean & Green business models.
▪ How is design quality retained in sustainable manufacturing?
PT
▪ Elaborate ‘Sustainable design methodology for AM’
▪ List the design guidelines and rules.
N
▪ Write down the characteristics of sustainability in metal
additive industry.
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PT
EL
EL
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Dr. Amandeep Singh
Imagineering Laboratory
IIT Kanpur
▪ Optimize for printing
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▪ Optimize for washing
▪ Optimize for sintering
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▪ General strategies
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Identify Critical Dimensions
PT
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Maximize Bed Contact
Source:
https://markforged.com/3d-printers/metal-x
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Reduce Supports
PT
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Optimize Your Production Workflow
Source:
Eliminates Supports Simplify Support Removal
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PT
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Source:
Shell Out Thick Parts
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PT
Wash Bowls Upside Down
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Source:
Solid triangular infill wash time
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PT
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Solid triangular infill dry time
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Reduce Stress Concentrations
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Ensure Features are Well Balanced
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Disable Part Rafts
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Use Pins for Alignment Features
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PT
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Separate Printed from Simple Features
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Isolate Properties with Modular Features
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Source:
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Source:
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EL

Growth of additive manufacturing

Efficient: The product should consume 90% less material,

PT 3. Measure the environmental

Additively manufactured titanium bottle opener

▪ Do not build the same parts designed for conventional manufacturing

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