Handbook of Sustainability in Additive Manufacturing: Volume 2

120 Pages·2016·4.09 MB·English

by  Subramanian Senthilkannan Muthu

Environmental Footprints and Eco-design
of Products and Processes
Subramanian Senthilkannan Muthu
Monica Mahesh Savalani E ditors
Handbook of
Sustainability
in Additive
Manufacturing
Volume 2
Environmental Footprints and Eco-design
of Products and Processes
Series editor
Subramanian Senthilkannan Muthu, SGS Hong Kong Limited,
Hong Kong, Hong Kong SAR
More information about this series at http://www.springer.com/series/13340
Subramanian Senthilkannan Muthu
Monica Mahesh Savalani
Editors
Handbook of Sustainability
in Additive Manufacturing
Volume 2
123
Editors
Subramanian SenthilkannanMuthu Monica MaheshSavalani
Environmental Services Manager-Asia Department ofIndustrial andSystems
SGSHong KongLimited Engineering
Hong Kong TheHong Kong Polytechnic University
Hong Kong Hong Kong
Hong Kong
ISSN 2345-7651 ISSN 2345-766X (electronic)
Environmental Footprints andEco-design of ProductsandProcesses
ISBN978-981-10-0604-3 ISBN978-981-10-0606-7 (eBook)
DOI 10.1007/978-981-10-0606-7
LibraryofCongressControlNumber:2016930176
©SpringerScience+BusinessMediaSingapore2016
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Contents
Energy Efficiency of Metallic Powder Bed Additive
Manufacturing Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Konstantinos Salonitis
Environmental Impact Assessment Studies in Additive
Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Olivier Kerbrat, Florent Le Bourhis, Pascal Mognol
and Jean-Yves Hascoët
Sustainability Based on Biomimetic Design Models. . . . . . . . . . . . . . . . 65
Henrique A. Almeida and Eunice S.G. Oliveira
Sustainable Frugal Design Using 3D Printing. . . . . . . . . . . . . . . . . . . . 85
Ian Gibson and Abhijeet Shukla
Carbon Footprint Assessment of Additive Manufacturing:
Flat and Curved Layer-by-Layer Approaches . . . . . . . . . . . . . . . . . . . 101
Subramanian Senthilkannan Muthu and Savalani Monica Mahesh
v
Introduction
This Handbook of Sustainability in Additive Manufacturing is planned to be
published in two volumes and the current one is the second volume which carries
five very informative and well-written chapters. Dealing with the core concepts
of the subject, these five topics are written by experts in the field.
Chapter“EnvironmentalImpactAssessmentStudiesinAdditiveManufacturing”,
authored by Dr. Olivier Kerbrat, Dr. Florent Le Bourhis, Pr. Pascal Mognol, and
Pr.Jean-Yves Hascoëtrevolvesaround characterizing theenvironmentalimpactof
additivemanufacturingprocesses.Inaddition,theauthorsstudyanewmethodology
which isusedto evaluate theenvironmental impact ofa part from its CAD model.
Anindustrialexampleisalsostudiedanditshowsthatmaterialconsumptionhasan
important impact and has to be taken into consideration for a complete environ-
mentalimpact assessment.
Chapter “Sustainability Based on Biomimetic Design Models”, written by
HenriqueA.AlmediaandMarioS.Correiafocusesonworkswhichaimtoevaluate
the ecological impact of the support production methodologies in order to deliver
awarenesstotheusersofextrusion-basedsystemsforalowerenvironmentalimpact
assessment. The extra production time involved in the production of the support
structures and the support structure removal is evaluated.
Chapter “Energy Efficiency of Metallic Powder Bed Additive Manufacturing
Processes”,authoredbyKonstantinosSalonitisdiscussesthesustainabilityissuesin
relation to the processing of metallic powders with additive manufacturing pro-
cesses. In addition, the sustainability at various levels was studied to show the
variations. Furthermore, the basics for modelling the finite element process were
discussedinrelationtotheenergyefficiencyandtheoptimizationoftheprocess.In
general, during the processing of metallic powders, the preheating of the raw
material is the key energy consumer; alternative methods of preheating were dis-
cussed and compared.
Chapter “Carbon Footprint Assessment of Additive Manufacturing: Flat and
Curved Layer-by-Layer Approaches”, written by Subramanian Senthilkannan
Muthu and Savalani Monica Mahesh describes and discusses the carbon footprint
vii
viii Introduction
assessment of the fused deposition modelling process and its adapted technique,
namely the curved fused deposition modelling process. Preliminary investigations
haveindicatedthatcurvedFDMpartsarestrongerthanthosemadeusingtheFDM
process. However, the initial carbon footprint does indicate that the material usage
and processing time of the curved FDM process are higher than those of the FDM
process. The authors have recommended a fuller investigation of the sustainability
issues of these two processes before in-depth conclusions can be drawn.
Chapter“SustainableFrugalDesignUsing3DPrinting”,authoredbyIanGibson
and Abhijeet Shukla describes and discusses sustainable solutions which can be
achieved through the fusion of 3D printing with frugal approaches in design and
engineering. 3D printingtechnologies have forced many torethink how we design
andturnthisgroupoftechnologiesandprocessesintoanewbusiness.Thechapter
explores the product design and development process in relation to frugal and
sustainableconceptsandhow3Dprintingandrelatedtechnologiesinfluencethem.
Thischapterhighlightshowfrugal designsenable designing forlow-costsolutions
tomanyimportantproblemsandhowthiscouldalsoassistwiththedevelopmentof
low-cost and accessible machines which use recycled materials.
The editors would also like to express their gratitude to all the contributing
authors.
Subramanian Senthilkannan Muthu
Monica Mahesh Savalani
fi
Energy Ef ciency of Metallic Powder Bed
Additive Manufacturing Processes
Konstantinos Salonitis
Abstract Metallic powder bed additive manufacturing processes have evolved a
lotoverthelastfewyears.Anumberofalternativeprocesseshavebeendeveloped
and are classified in the present chapter. In order for these processes to deliver
metallicparts,alargeamountofenergyisdeliveredtothepowderthatisusedasa
rawmaterial.Theimplicationstothesustainabilityarediscussedandsustainability
key performance indicators are presented. This chapter presents a comprehensive
reviewoftherelevantliteratureofthestudiespresentedontheenergyefficiencyof
metallic powder bed additive manufacturing processes and the key challenges for
improving it. Furthermore, modelling of theprocesswithfinite element simulation
is discussed for the estimation of the energy efficiency and the optimisation of the
process under this prism. Because the preheating of the raw material is the key
energy consumer, the alternative methods are discussed and compared.
Keywords Additive manufacturing (cid:1) Energy efficiency, modelling
1 Introduction
Additive manufacturing (AM) processes were developed in the mid-1980s and
since then a number of processes have been presented. The key advantage of such
processes is the freedom that they provide to the designers for coming up with
product designs that cannot be manufactured conventionally. Conventional manu-
facturing processes, such as machining, pose limitations on the component
geometriesthatcanbeproduced.Theselimitationsoftenresultinstructuresthatare
inefficient, as many areas of a component have excess material that cannot be
removed physically or in a cost-effective way through conventional methods. AM
allows components to be manufactured in a bottom-up approach with laying
K.Salonitis(&)
ManufacturingDepartment,CranfieldUniversity,CollegeRoad,B50,
CranfieldMK430AL,UK
e-mail:k.salonitis@cranfield.ac.uk
©SpringerScience+BusinessMediaSingapore2016 1
S.S.MuthuandM.M.Savalani(eds.),HandbookofSustainability
inAdditiveManufacturing,EnvironmentalFootprintsandEco-design
ofProductsandProcesses,DOI10.1007/978-981-10-0606-7_1
2 K.Salonitis
material only where it is required. The main technological breakthrough that
allowed the development of both desktop processes as well as AM, was the evo-
lution of computer and information technology, and especially the various
computer-assisted technologies in the manufacturing area, such as computer-aided
design (CAD), computer-aided manufacturing (CAM), and computer-aided engi-
neering(CAE).Oneofthekeyadvantagesofsuchprocessesthusisthefabrication
of components and even complete assemblies directly derived from CAD models
without the need for process planning in advance of manufacturing. Various
methods that allow the ‘building’ of three-dimensional objects in sequence by
adding layers over each other have been developed [1].
AMtechnologyhasarelativelyshorthistoryofabout25yearsandithasgrown
largelysinceitsinvention.AccordingtotheWohlersReport[2],theAMprojected
value for 2015 is $4 bn, and will reach $6 bn in 2017 and almost $11 bn in 2021.
However,althoughitisbecomingmoreandmoremature,andoftenclaimedasthe
‘next industrial revolution’ there are still a number of challenges for successful
commercialisation. AM technology challenges are related to the materials, the
availableCAD software, thedata management, thesustainability,theaffordability,
theprocessspeed,theprocessreliability,theintellectualproperty,andthestandards
to name a few [3]. The design for AM has been also identified as a key challenge,
highlighting that for exploiting the capabilities that AM processes offer, the
designers have to adapt their approach to the AM technology, not replicating the
existing methods and philosophies established for conventional processes.
Additive manufacturing is the process of fabricating an artefact (geometrically
defined product), which is derived from a model, initially generated using a
three-dimensional computer-aided design (3D CAD) system, directly without the
need for process planning. Rapid prototyping belongs directly to additive manu-
facturing, but differentiates itself through the intended means of rapid prototyping,
whichisdescribedas‘processesforrapidlycreatingasystemorpartrepresentation
(like a prototype) before final release or commercialization’. Additive manufac-
turing processes can be classified in three different categories depending on the
status of the material used to create the artefact during the process, for example,
powder based, liquid based, and solid based as depicted in Fig. 1. A large number
ofdifferent AM processeshave beendevelopedintheshorthistory ofAM;fewof
them though survived over time. Common materials are aluminium, steel alloys,
precious metals, plastics usedin a powder form, and paper; but wood, wax, paper,
clay, concrete, sugar, and chocolate are possible to be used as filament. The most
widespread AM processes include:
(cid:129) Selectivelasersintering(SLS)isasinteringprocesswhereasurfaceofapowder
bed is fused with a high-power laser. Thus, a geometrically defined product is
built up layer by layer and the nonmelted powder is cleaned away and can be
recycled. SLS is suitable for highly complex parts that contain undercuts
because the powder is supporting the structure.
(cid:129) Laser engineering net shaping (LENS) is a process where a geometrically
definedproductisbuiltbyinjectingmetalpowderintoamoltenpool.Thepool