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Sustainability of 3D Printing: A Critical Review and Recommendations

Conference Paper · June 2016


DOI: 10.1115/MSEC2016-8618

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Proceedings of the ASME 2016 International Manufacturing Science and Engineering Conference
MSEC2016
June 27-July 1, 2016, Blacksburg, Virginia, USA

MSEC2016-8618

SUSTAINABILITY OF 3D PRINTING: A CRITICAL REVIEW AND


RECOMMENDATIONS

Zhichao Liu Qiuhong Jiang


Department of Mechanical Engineering, Dalian Department of Mechanical Engineering, Dalian
University of Technology University of Technology
Dalian, China Dalian, China
Department of Industrial Engineering, Texas Tech
University
Lubbock, TX, USA

Yang Zhang Tao li Hong-Chao Zhang


Department of Industrial Department of Mechanical Department of Mechanical
Engineering, Texas Tech Engineering, Dalian University of Engineering, Dalian University of
University Technology Technology
Lubbock, TX, USA Dalian, China Dalian, China
Department of Industrial
Engineering, Texas Tech
University
Lubbock, TX, USA

ABSTRACT 1. INTRODUCTION
3D printing has been recognized as an efficient and Since late 1980’s, when the first Stereo Lithography
sustainable technology in the fields of advanced manufacturing. Apparatus (SLA) machine was developed, a sustainable
In the past few years, a considerable research, including basic resolution to reduce waste and production cycle has come
theoretical research, technology innovation and industries around [1]. From the fabrication of complicated jet engine parts
application, have been conducted to promote 3D printing for a to simple cups, 3D printing is being regarded as an alternative
better performance in manufacturing. However, the benefits of and more efficient way to develop new product. Statistics show
3D printing from environmental perspective are still to be seen that the global market for 3D printing will be worth $16.2
and its sustainability is also a mystery. This paper presents a billion by 2018, which is four times larger than that of 2014 [2].
critical review about the qualitative and quantitative Holding a competitive advantage in materials efficiency
environmental impact of 3D printing to provide a and less processing procedures, the technological and economic
comprehensive understanding of 3D printing for the public and benefits of 3D printing has been widely reported and
provide a better guide for the future research. In addition, based documented, and it became especially popular in the United
on the principle of multi-objective optimization, this paper States in the last decade. Web of Science suggests that more
proposes a novel framework for 3D printing processes than 1200 papers have been published from 2005-2015 within
sustainability assessment and improvement by integrating the the US, and it still presents a trend of fast increase in the basic
product Computer Aided Design (CAD) and Life Cycle theory exploration and technology development. Although
Assessment (LCA). At last, recommendations about major several survey about 3D printing have been documented [3~7],
concerns when analyzing the sustainability of 3D printing are almost all of them are written on behalf of its categories,
put forward, which might be considered for the coming processes, quality and cost benefits or focus on environmental
research. impact of rapid prototyping technologies before 2006, the
environmental issue in terms of this new coming technology is
KEYWORDS still to be seen.
3D printing; Sustainability; Environmental impact;

1 Copyright © 2016 by ASME


Being different from traditional manufacturing processes, bloodstream and lead health risk, especially for those with
3D printing starts from modeling, going through printing and asthma [11].
finishing, it saves the traditional processes of casting, forging Life cycle assessment (LCA) is a useful tool for
and rough machining without reducing the final part quality. quantifying the environmental impact over the entire life cycle
Difference of processes in 3D printing and traditional of a product [12]. As a systematic, phased approach, the LCA
manufacturing is shown in Table 1. process consists of four components: goal definition and
scoping, inventory analysis, impact assessment, and
TABLE 1 DIFFERENCE OF PROCESSES IN 3D PRINTING interpretation [13]. Extensive research about LCA method and
AND TRADITIONAL MANUFACUTING application have been conducted during the past few decades
Traditional [14-18]. Apart from environmental benefit, cost-effectiveness is
Items 3D printing
manufacturing another key components during product design stage. Economic
Forming method Additive Subtractive
Life Cycle Assessment (also called LCC) is applied to compare
Powders, Filament and Block, Bar, Plate,
Materials cost effectiveness of different business decisions or investments
Tapes, etc. etc.
Efficiency Higher Lower
from the point of view of a decision maker [19]. Generally,
Production Waste Less More process of LCC analysis considers the first two stages of LCA,
Built time Hours to days Days to months which is goal definition and scoping, life cycle inventory
Cost Higher Lower analysis. As a useful tool to determine the most cost-effective
Life cycle Shorter Longer option among different competing alternatives, LCC is now
Required widely used in purchase, operation, maintenance and disposal of
Ordinary workers Skillful workers
employees a product. Recently, increasing attention has been paid to LCC
Suitable Making prototypes, in a wide range from governmental usage to industrial
Batch production
applications Complex shapes applications and the theoretical methodology and practical
application has already been documented extensively [20-25].
With the increasing awareness of resource saving and The public opinion are divergent about the sustainability of
environment protection, environmental issues has been paid 3D printing, but what is the objective situation of the
more attention during product manufacturing processes. Both environmental impact of 3D printing at the present and how to
governments and corporations are being pushed by inside and evaluate the environmental impact of 3D printing from a
outside activists and consumers to pay more attention to the scientific way is a problem worth studying. This paper
environmental impacts of the product they buy. As a new illustrated the sustainability of 3D printing through
technology, the sustainability survey is necessary for 3D summarizing and analyzing published works. Meanwhile, a
printing before its extensive industrial application. scientific way to evaluate the environmental impact of 3D
Being different with the consensus of the technological printing is presented in the future perspective combined with
benefits of 3D printing, a different opinion is held on its the current research topic. This paper presents a comprehensive
sustainability in academic field. It is claimed that the in-home understanding of 3D printing for the public and it will provide a
3D printing is an effective way to recycle and upcycle with better guide for the future research.
minimal waste, meanwhile, it can reduce the environmental
impact by lessening transportation needs and packaging, thus to 2. SUSTAINABILITY SURVEY OF 3D PRINTING
reduce the air pollution and less plastic pollution, which are two
major contributions to current climate crisis [8]. However, it is In order to present the sustainability of 3D printing and to
also suggested that 3D printing is not always environmental demonstrate the situation of different 3D printing method, a
friendly under a certain situation when comparing survey of recent papers and reports about environmental and
environmental impacts of additive manufacturing vs traditional cost analysis of 3D printing from Google Scholar and Web of
machining for plastic materials, and the sustainability of Science is conducted, and more than 20 typical papers/reports
additive manufacturing vs. Computer Numerical Control (CNC) among the existing publications have been selected and
machining depends primarily on the percent utilization of each separated into two categories (Positive and Negative) referring
machine [9]. In 2009, research at MIT's Environmentally to the environmental impact of 3D printing.
Benign Manufacturing program showed that laser direct metal
deposition used hundreds of times the electricity as traditional 2.1 Positive Opinions
casting or machining [10]. Moreover, Stephens et al. pointed Based on layer by layer fabrication, many advantages can
out that when heating the plastic and printing small figures, the be achieved by 3D printing, for example, material waste is
machines using polylactic acid (PLA) filament emitted 20 significant reduced [26] and also the supporting material, which
billion ultrafine particles per minute, and the acrylonitrile is utilized to make the increasingly exotic geometries possible,
butadiene styrene (ABS) emitted up to 200 billion particles per is able to be recycled into raw material after 3D printing is
minute. These particles can settle in the lungs or the finished. Meanwhile, many CNC machined parts are produced
from block, which is always significantly more than the part that

2 Copyright © 2016 by ASME


is to be produced, it is said that the ratios of waste of materials part than traditional injection molding, and inkjet printer had
with the material ends-up in the final part can reach up to 19:1 significantly worse ecological impacts than traditional
[27]. Although the waste materials can be recycled back, it will machining [9].
also generate second energy and resource consumption as well For the energy use, some researchers hold a totally
as environmental emissions. In contrast with traditional different idea compared with those who insist that 3D printing
manufacturing process, 3D printing release less carbon dioxide could reduce the energy consumption. When comparing
because of less energy usage comparing with the traditional industrial-grade printers to injection molding machines, Kurman
pattern of factory manufacturing and shipped to warehouse. revealed that a large amount of electrical energy will be
Kreiger et al. indicated that the cumulative energy demand of consumed during the 3D-printing process, which is estimated 50
manufacturing polymer products can be reduced by 41−64% to 100 times more electrical energy than injection molding to
with existing low-cost open-source 3D printers [28]. Besides, make an object of the same weight [32]. Similarly, Yoon et al.
casting, forging and rough machining transportation and pointed out that the specific energy consumption of 3D printing
packaging which are essential during the traditional processes is estimated to be 100 times higher than that of
manufacturing processes can be simplified or shortened in 3D conventional bulk-forming processes. When comparing the
printing processes, thus, it is reasonable that 3D printing will energy consumption of three different manufacturing processes,
generate less environmental impact. they concluded that injection molding consumed the largest
Apart from the consideration of material and energy, in the amount of energy, followed by FDM, and machining [33].
life cycle of 3D printing processes, the transportation and Indeed, due to the characteristics of several powders, some
manufacturing carbon footprint can be reduced during the negative environmental emissions maybe appear during 3D
design stage, because the manufacturing processes will be printing processes. Kim et al. evaluated the emissions
basically confirmed once the structure of the product is characteristics of hazardous material during fused deposition
determined. The designer could modify the design strategy in modeling type 3D printing, they concluded that the 3D printing
the design stage and thus help to reduce the carbon footprint processes using ABS and PLA cartridge will generate 1.61 ×
before deliver it to the manufacturing. Moreover, the 1010 ea/min and 4.27–4.89 × 108 ea/min cartridge, which are
environmental impact can be further reduced by scaling back or adversely affect the environment and human health [34].
eliminating complex supply chains [29]. Besides, Mani et al. Conclusions about sustainability of 3D printing varies
claimed that additive manufacturing is more sustainable option under different situations, Former literature review indicates
because it requires no specialized tooling or fixtures and that different methods and materials using in 3D printing
capable to create on-demand spare parts, reducing or technology will generate different point of view in
eliminating inventory [30]. On the other hand, reading through environmental impact evaluation. In order to obtain an
the selected papers, the product built by 3D printing mostly objective environmental profile of 3D printing, some researcher
contain single raw material, when considering the end-of-life suggested using several assessment models to quantitatively
disposal strategy, the recycling process of single material reflect the actual environmental burden referring to this new
products is not as difficult as the recycling of products made of coming technology.
multiple materials [31].
Advantages of 3D printing, like less waste, no specialized 3. SUSTAINABILITY ASSESSMENT MODELING OF 3D
tooling, life cycle reduction, etc. enable it to be considered as PRINTING
more environmentally friendly than traditional manufacturing,
however, more efforts should be made to explore the 3.1 Literature Survey
environmental impacts of 3D printing, and a comprehensive When new technology comes, the sustainability evaluation
approach, like life cycle assessment, should be conducted to is necessary and it will help to provide references to guide the
capture the quantitative benefits and potential hazards when decision-makers to prevent the negative aspects. However, the
applying this new technology [5]. evaluation processes may come across many challenges.
Literature review indicates that sustainability assessment for 3D
2.2 Negative Opinions printing processes can be divided into two methods: qualitative
Being contradictory with the supporters who regard 3D analysis and quantitative analysis.
printing as more environmentally, researchers put forward some Due to the lack of process and material data, qualitative
different points of view. Some researchers claimed that 3D analysis is applied for most sustainability assessment and
printers are not necessarily less wasteful, especially in a modeling for 3D printing. With life cycle thinking approach,
nutshell, and also their waste is not necessarily recyclable. Kunnari et al. evaluated environmental performances of inkjet
Moreover, the transportation is a tiny part of most products’ printing and concluded that it is possible to make electronics
environmental impacts [9]. When quantitatively comparing the printing consume less primary energy than traditional
environmental impacts of additive manufacturing with lithography, but this conclusion are obtained based on an
traditional machining, Faludi indicated that at mass- limitation of a lack of process-specific data for both the printing
manufacturing scale, 3D printers have far higher impacts per processes and the materials [35]. Kellens suggested an

3 Copyright © 2016 by ASME


environmental impact evaluation model for 3D printing based section. Product CAD is the first step in 3D printing processes,
on multiple linear regression analysis, and applied the model to any decision related to the printing process, like materials
assess the energy and resource consumption and environmental selection, parameters variation, geometry change and processes
pollutions for Selective Laser Sintering (SLS) processes [36]. adjustment, will affect the sustainability of the final part. The
Similarly, Burkhart developed a framework to predict the final product CAD file is composed by different characteristics,
environmental impact of a commercial vehicle with additive which are the geometric features, such as false boss, hole,
manufacturing, and it can help to identify the improvement groove and chamfer, etc. that are processed during the CAD
opportunity to decrease the environmental impact of the vehicle stage. The essence of the method is to realize the integration of
[37]. However, the processes and components may be different Life Cycle Assessment (LCA) and product Computer Aided
when conducting 3D printing, therefore, the application of the Design (CAD) process. The general structure of proposed
proposed models is very limited due to its finite universality. framework is shown in Figure 1.
Bourhis et al. presented a new methodology for electric,
fluids and raw material consumptions assessment for a direct Sustainability assessment and
improvement system of 3D
metal deposition process [38, 39]. The method intend to predict printing
the environmental impact of 3D printing during the design step,
thus to minimize the whole consumption during the Product design
requirement and indicators
manufacturing step. The method focus on the prediction of
material and electricity consumptions and it did not consider the
specific environmental impact, like Global warming potential, Product family Product family
module (original) module (aboriginal)
and ozone depletion potential, etc.
With the help of professional and public databases,
Product family database Product CAD-LCA LCA of the
quantitative analysis for sustainability assessment of 3D marked with LCA value model components
printing become feasible and it can help to track and document
the environmental impact in each life cycle stage and major
Product redesign
contributing process. Life Cycle Assessment is a leading-edge
methodology to analyze the environmental benefits of 3D No No
printing quantitatively. It is indicated that compared with CNC Structure Process
change ? change ?
machining, Fused Deposition Modeling (FDM) could achieve
Yes Yes
the lowest ecological impacts [9] and that through 3D printing,
Module correlation Product structure Product Process correlation
the energy demand for manufacturing polymer products can be analysis design process design analysis
reduced by a half [28]. Also, aiming to reduce the energy
consumption during 3D printing processes, LCA is utilized to
No
investigate the effect of parameters in 3D printing on the final Satisfy the
requirement ?
energy consumption and environmental emission [40].
Being able to provide lightweight and cost effective Yes

designs, 3D printing is increasingly applied in aircraft Product Life


cycle analysis
components fabrication. By integrating engineering criteria, life
cycle environmental data and fuel use models, Huang et al. No
Satisfy the
predicted that the life cycle energy savings for aircraft requirement ?
components 3D printing can reach to 173 million GJ/year in
Yes
2050 [41].
Environmental evaluation models for 3D printing is helpful Product design
scheme output
for Eco design before the impletion of the final printing
processes, however, it can hardly satisfy the practical situation
of 3D printing due to its property of high instability, also most 3D printing

of the models are specific to the single environmental aspect. A


more persuasive way is to apply a quantitative method to FIGURE 1 GENERAL STRUCTURE OF PROPOSED
evaluate the sustainability, not only environmentally, but also FRAMEWORK
economic and technological, and tries to reflect the overall
benefits of 3D printing processes. The major procedures of the framework including four steps
that are listed as follows:
3.2 Proposed Framework
Aiming at make overall plans and take all factors into (1) Construction of product CAD-LCA model
consideration, a framework for 3D printing processes With product LCA method, environmental impact of each
sustainability assessment and improvement is proposed in this characteristic can be obtained and then the data is recorded in a

4 Copyright © 2016 by ASME


database, named as a product family. Once the product CAD is properties. Therefore, a systematic multi-objective optimization
finished, with the marked LCA information in product family, is necessary. The objective in this framework is to optimize the
the CAD information can be transferred to relative product performance (P), process cost (C) and environmental
environmental impact, then the product CAD-LCA model can impact (T) and the objective function is defined in equation (2).
be constructed with the mapping relationship between separate
characteristic and related LCA result. Min   P 1 ( X ), C0 ( X ), D0 ( X ), Te ( X ) (2)
The final environmental impacts indicator of each Subject to[P]  P  0, C0  [C0 ]  0, D0  [ D0 ]  0, Te  [Te ]  0
characteristic is calculate by Eq.1:

m
Where, C0, D0 and Te is the actual process cost, process
n ∑EI i × Gi
(1)
time and environmental impact; [P] is the lowest product
performance, and [C0], [D0], [Te] is the highest production cost,
EI = ∑Vk × ( i =1 ) the longest process time and highest environmental impact
k =1 Rk
limited by the company.
Where, EI is the final environmental impact indicator; Gi is
the value of ith substance in life cycle inventory; EIi is (4) Seamless connection of LCA and CAD software
characterization factor of ith substance to kth indicator, k=1~5; The time for new product design is very limited and it is
Rk is the reference value of kth indicator; Vk is the weight factor required to reduce the research and development period, then
of kth indicator, and m is the number of substance related to kth the evaluation process need to be not only effective but also
indicator, n is the number of the indicators. efficient. Therefore, seamless connection of LCA and CAD
software can help the designers finish the evaluation instantly.
(2) Local Redesign The integrated framework for the seamless connection of LCA
The final environmental profile of the former designed and CAD software is shown in Figure 2.
product can help the process planner identify the process or
parameter that generates largest environmental impact, and then CAD system
improvement opportunity can be provided. Redesign process Feature 11
Transfer Process
ID= 11
should follow the basic principle that the geometrical feature Part 1 Feature 12
after redesign should not only satisfy the original quality Transfer Process
Part 2 ……
requirement, but also reduce the environmental impact and Product
ID= 1i
Feature 1n
bring about cost-savings. For example, assuming a product has ……

totally n components, which are represented as Ci, i=1~m, and Part n Computer Programming (Java, C++)

the characteristics of ith component is represented as Fj, j=1~n


and Ei: Life cycle assessment result of jth characteristic. LCA
API
Assume that there are two design options for ith component, LCA system
and the materials for the two options are same but the structure ID= 11 ID= 12 ID= 1n
and process are different (one of the characteristics is changed 1.Classification &

from F1 to F2), after module and process correlation analysis, Recourse Energy Environment Impact Characterization
consumption Consumption al Emissions Analysis
they can both satisfied with the requirements. Their 3D printing 2.Normalization
3.Weighting/Grouping
process begin with CAD, going through slicing, converting and
deposition. Once the structure is determined in the CAD stage,
the following processes as well as relative environmental impact Databases: BOM, Volume, Mass, Cost, Tensile Strength, Environmental Impact. etc.

are basically confirmed. Before the slicing step, we can


compare the environmental impact of the two options, if
Ej1>Ej2, select option 1 as the optimal design. The cost analysis FIGURE 2: INTEGRATED FRAMEWORK FOR LCA AND
will be much alike the process and in this case, the decision- CAD SOFTWARE
maker can compare the cost and environmental impact of each
method and make an overall sustainable approach. The new The proposed framework can be used in all kinds of 3D
design will be evaluated with the same procedure in step (1). printing methods and the environmental profile for each feature
modeled in CAD can be directly presented on an independent
(3) Multiple objective optimization module designed by Application Program Interface (API), thus
Usually, the manufacturing cost, performance and help to provide a quantitative way to evaluate the sustainability
efficiency are the selected as the evaluation standard for a new of the 3D printing. The current commercial LCA software, like
process or new design, the environmental impact are neglected GaBi, Simapro, and E-balance can provide sufficient
in most cases. However, the improvement on environmental environmental impact information, and the biggest challenge is
performance may bring about confliction for cost and

5 Copyright © 2016 by ASME


the computer programming (Java or C++) to realize the used, there exist both positive and negative opinions as for the
seamless connection of LCA and CAD software. environmental impact of 3D printing, and it is not easy to draw
an exact conclusion. A reasonable conclusion is that the
4 FUTURE PERSPECTIVES environmental impact of 3D printing is case-by-case depending
on specific situation.
3D printing is moving in an all-around way and all clues In order to better evaluate the sustainability of 3D printing
are indicating that it will continue to expand in many areas in processes quantitatively and better guide the decision-makers,
the future. In the meanwhile, with the increasing awareness of this paper proposed a framework for 3D printing processes
sustainable manufacturing, the sustainability issue of 3D sustainability assessment. The integration of product CAD and
printing has been paid attention gradually. A comprehensive LCA can realize the improvement in the early design stage,
understanding can help to promote the development of 3D which is an essential step for 3D printing.
printing better and faster. The future trend for 3D printing To realize the sustainable manufacturing is the goal in
sustainability assessment needs to address the following points. current industries, it’s unclear exactly how far we could go with
3D printing or if it will finally be marked as purely sustainable,
(1) Scientific environmental impact evaluation of 3D printing but certainly it is a worthy study area now and in the future.
processes
As mentioned before in this paper, different 3D printing ACKNOWLEDGMENTS
processes may generate totally different result referring to its The authors gratefully acknowledge the support of and the
environmental impact. It is not only relative to various National Basic Research Program of China (Grant No.
processing principle, but also involved in the powders itself. 2011CB013406).
The reasonable conclusion is that environmental impact of 3D
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