Sustainability of additive manufacturing: An overview on its energy demand and environmental impact

Additive Manufacturing (AM) has been rapidly developing over the last decade. It shows great potential in reducing the need for energy- and resource-intensive manufacturing processes, which in turn reduces the amount of material required in the supply chain, and enables more environmentally benign practices. However, the question of how to realize these potential benefits has received little attention. This paper aims to provide an overview of the Sustainability of Additive Manufacturing (SAM). The context of the SAM is introduced, with a focus on energy and environmental impacts. Resource consumption is identified as the most important aspect. Examination from a life cycle perspective is also presented, with explicit discussions on opportunities to reduce energy and material consumption through design, material preparation, manufacturing, usage, and end-of-life treatment. Statistical data analysis provides an overview of impact forecasts, highlighting the importance of and need for thorough research on sustainability. The eco-design concept enabled by AM is identified as the most promising and effective technology, further extending and completing its design capability. This also determines the opportunities for energy and environmental optimization in subsequent processes. Most existing research is in process- and system-specific modeling, and few AM processes and systems have been studied, with generally premature conclusions. General models for each type of AM process are still necessary. Lastly, five research priorities are suggested: improve systematic data integration and management, correlate energy and quality, develop intelligent machinery, focus on material preparation and recycling, and discover innovative applications using AM.