Year: 2025
Type: article
Abstract: Laser powder bed fusion of metals (PBF-LB/M) is increasingly recognised as a pivotal technology to drive the green transition in manufacturing. While its high material efficiency and minimised resource usage offer sustainability benefits, the energy-intensive nature of the process poses a major environmental challenge. This study explores potential avenues to asymptotically reduce the carbon footprint of the PBF-LB/M process through a multifaceted approach, to realise its full potential as a sustainable manufacturing process. A cradle-to-gate scope is used to identify the key drivers of environmental impact and propose a structured sequence of targeted optimisations of the operating conditions, each quantified using a life cycle approach. Key strategies to reduce environmental impact—including switching to renewable energy, using lower impact gases such as nitrogen, increasing recycled content, on-site nitrogen generation and optimising component design—are progressively implemented and their cumulative impact is quantitatively assessed within the GHG Protocol. The paper provides a clear roadmap through a sequence of scenarios for sustainable PBF-LB/M, to meet the requirements of responsible manufacturing.
Source: Carbon Research
Institution: University of Modena and Reggio Emilia
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid:
Funder: European Commission
Awards: G1175062043, G2649423451, G375662711
OpenAlex ID: W4415372107