Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing
Decarbonizing industrial manufacturing is a significant challenge in the effort to limit the impacts of global climate change. Additive manufacturing (AM) is one pathway for reducing the impacts of manufacturing as it creates parts layer-by-layer rather than by removing (i.e., subtracting) material...
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| Language: | English |
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MDPI AG
2025-06-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/7/214 |
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| author | Christopher Price Kristina Armstrong Dipti Kamath Sachin Nimbalkar Joseph Cresko |
| author_facet | Christopher Price Kristina Armstrong Dipti Kamath Sachin Nimbalkar Joseph Cresko |
| author_sort | Christopher Price |
| collection | DOAJ |
| description | Decarbonizing industrial manufacturing is a significant challenge in the effort to limit the impacts of global climate change. Additive manufacturing (AM) is one pathway for reducing the impacts of manufacturing as it creates parts layer-by-layer rather than by removing (i.e., subtracting) material from solid stock as with conventional techniques. This reduces material inputs and generates less waste, which can substantially lower life cycle energy consumption and greenhouse gas emissions. However, AM adoption in the manufacturing sector has been slow, partly due to challenges in making a strong business case compared with more traditional and widely available techniques. This paper highlights the need for the development of simple screening analysis tools to speed the adoption of AM in the manufacturing sector by providing decision-makers easy access to important production life cycle emissions, and cost information. Details on the development of two Microsoft Excel software tools are provided: upgrades to an existing tool on the energy and carbon impacts of AM and a new tool for analyzing the major cost components of AM. A case study applies these two tools to the production of a lightweight aerospace bracket, showing how the tools can be used to estimate the environmental benefits and production costs of AM. |
| format | Article |
| id | doaj-art-5dd3ce7789e54aefb6896b49f89fe010 |
| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-5dd3ce7789e54aefb6896b49f89fe0102025-08-20T03:36:18ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-06-019721410.3390/jmmp9070214Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive ManufacturingChristopher Price0Kristina Armstrong1Dipti Kamath2Sachin Nimbalkar3Joseph Cresko4Oak Ridge National Laboratory, Manufacturing Science Division, One Bethel Valley Road, NTRC, 2360HVC, MS 6472, Oak Ridge, TN 37830, USAOak Ridge National Laboratory, Manufacturing Science Division, One Bethel Valley Road, NTRC, 2360HVC, MS 6472, Oak Ridge, TN 37830, USAOak Ridge National Laboratory, Manufacturing Science Division, One Bethel Valley Road, NTRC, 2360HVC, MS 6472, Oak Ridge, TN 37830, USAOak Ridge National Laboratory, Manufacturing Science Division, One Bethel Valley Road, NTRC, 2360HVC, MS 6472, Oak Ridge, TN 37830, USAIndustrial Technologies Office, U.S. Department of Energy, 1000 Independence Avenue SW, Washington, DC 20585, USADecarbonizing industrial manufacturing is a significant challenge in the effort to limit the impacts of global climate change. Additive manufacturing (AM) is one pathway for reducing the impacts of manufacturing as it creates parts layer-by-layer rather than by removing (i.e., subtracting) material from solid stock as with conventional techniques. This reduces material inputs and generates less waste, which can substantially lower life cycle energy consumption and greenhouse gas emissions. However, AM adoption in the manufacturing sector has been slow, partly due to challenges in making a strong business case compared with more traditional and widely available techniques. This paper highlights the need for the development of simple screening analysis tools to speed the adoption of AM in the manufacturing sector by providing decision-makers easy access to important production life cycle emissions, and cost information. Details on the development of two Microsoft Excel software tools are provided: upgrades to an existing tool on the energy and carbon impacts of AM and a new tool for analyzing the major cost components of AM. A case study applies these two tools to the production of a lightweight aerospace bracket, showing how the tools can be used to estimate the environmental benefits and production costs of AM.https://www.mdpi.com/2504-4494/9/7/214additive manufacturinglife cycle assessmentGHG emissionscost analysisenergy savings |
| spellingShingle | Christopher Price Kristina Armstrong Dipti Kamath Sachin Nimbalkar Joseph Cresko Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing Journal of Manufacturing and Materials Processing additive manufacturing life cycle assessment GHG emissions cost analysis energy savings |
| title | Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing |
| title_full | Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing |
| title_fullStr | Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing |
| title_full_unstemmed | Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing |
| title_short | Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing |
| title_sort | novel tools for analyzing life cycle energy use carbon emissions and cost of additive manufacturing |
| topic | additive manufacturing life cycle assessment GHG emissions cost analysis energy savings |
| url | https://www.mdpi.com/2504-4494/9/7/214 |
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