This enormous quantity of by-products with no further use is a significant source of pollution on the planet, particularly as the vast majority of it is not disposed of responsibly. However, thanks to advances in additive manufacturing and 3D printing, it is now possible to envision a future where production processes generate minimal waste, and materials are used with far greater efficiency. These methods use only the necessary amount of material, drastically reducing waste and ensuring complete precision.
How Does Additive Manufacturing Work?
Unlike traditional manufacturing, which typically involves subtracting material through processes such as cutting or drilling, additive manufacturing creates a product by building it up layer by layer. 3D printing is the most widely known form of additive manufacturing, but there are many different processes which fall under this category.
- 1. Fused Deposition Modelling (FDM): As one of the most commonly used types of 3D printing, FDM printers are popular for their versatility and cost-effectiveness. They operate by extruding thermoplastic filaments, layer by layer, to create an object from a 3D model.
2. Stereolithography (SLA): This type of manufacturing uses a laser to cure liquid resin layer by layer into hardened plastic. Its high resolution and smooth surface finish makes SLA popular for applications which require great detail and precision.
3. Selective Laser Sintering (SLS): SLS uses a laser to selectively fuse together powdered material, usually nylon or a type of polymer, to form a solid structure. This technique is used in applications where strong, functional parts are needed and does not require a support structure during printing.
One of the primary benefits of additive manufacturing is its minimal use of material, generating an average of 70-90% less waste2 than traditional subtractive manufacturing processes. By precisely depositing material where it is needed, 3D printing ensures that almost every gram of material contributes to the finished product. This not only reduces waste, but also lowers the cost of raw materials, making production more economical and environmentally friendly.
Additionally, 3D printing offers substantial energy savings by streamlining the manufacturing process and eliminating multiple intermediate stages, such as raw material extraction, processing, machining and assembly. Since many 3D printing technologies use thermoplastic materials, there is a higher potential for recycling than conventional processes, as they can be melted down and reused many times over.
Additive manufacturing also facilitates the production of custom and on-demand parts, reducing the need for large inventories. This is particularly useful for industries with high variability and low-volume production needs, such as healthcare and aerospace.
Case Study: General Electric (GE) Aviation
The aerospace industry has been a pioneer in adopting additive manufacturing due to its requirement for high-performance, lightweight components. GE Aviation, in particular, is at the forefront of this innovative production process, achieving a significant breakthrough in efficiency and performance with their LEAP engine fuel nozzle.
Previously, this component consisted of 20 different parts, each requiring multiple manufacturing steps. But by utilising 3D printing, GE was able to consolidate these parts into a single, unified component, reducing the weight of the nozzle by 25%3 and improving its durability and performance. Since the start of this project in 2015, GE Aviation has printed hundreds of thousands of LEAP nozzles, and the applications for 3D printing in civil aviation parts are rapidly expanding.
The use of additive manufacturing in aerospace design also contributes to a lighter aircraft, with one study showing that if 3D printed components are used to their full potential, airplane fuel consumption could be reduced by as much as 6.4%4.
What Are the Challenges for Additive Manufacturing?
Despite the numerous sustainable and operational benefits of additive manufacturing, the industry still faces several challenges that must be addressed for its potential to be fully realised.
Material Constraints:
The range of materials that can be used for manufacturing is currently quite limited in comparison to other traditional methods. Most 3D printing processes are constrained to specific plastics, metals and composites, so expanding the variety of usable materials remains a key challenge. However, ongoing research and development into new polymers, metals and composites that are more versatile and sustainable will broaden the scope of applications for additive manufacturing in the future.
Production Speed:
Another significant drawback for additive manufacturing is its production speed, making it less suitable for high-volume production. While advancements have been made in techniques such as continuous liquid interface production (CLIP) and multi-jet fusion (MJF) to produce parts more rapidly without sacrificing quality, this technology needs to improve significantly in order to be widely adopted by industries.
Regulatory and Quality Assurance:
Ensuring consistent quality and meeting regulatory standards is also a challenge, particularly in industries such as aerospace and healthcare. Advances in AI, IoT and blockchain can mitigate these difficulties, however, by enhancing the capabilities of additive manufacturing and enabling real-time monitoring of the production process.
Author: Shirley Carruthers - Content Creator at ParkerSteel
Resources:
Industrial Waste Facts
Sustainable Manufacturing
GE Aviation 100,000th 3D Printed Fuel Nozzle
ScienceDirect PDF
