Work

University Laboratory-Scale Carbon Footprint and Cost Comparison of Atomized and Short-Chip-Milled Aluminum Powders for TPU–Al Composite Specimens

Year: 2026

Type: article

Abstract: This study compares the cradle-to-gate carbon footprint and production cost of TPU–Al composite specimens manufactured by fused filament fabrication (FFF) using two aluminum-powder sourcing routes: commercial gas-atomized powder imported from the United Kingdom and powder produced by low-energy grinding of 7075 machining chips under laboratory conditions (TRL 3–4). Stage-resolved inventories were compiled for both systems, and an attributional life cycle assessment (LCA) focused on climate change (CO 2 -eq) was performed. The results show that Scenario 1 is dominated by the electricity demand of extrusion and printing, whereas Scenario 2 is overwhelmingly dominated by the high-energy intensity of chip grinding. Recycling–allocation rules strongly affect the comparative outcome: under a 100:0 recycled-content perspective, the recycled-powder route appears favorable, but under 50:50 or 0:100 allocation, it becomes substantially more carbon-intensive. Cost analysis indicates that chip-derived powder is economically competitive due to avoided atomization and importation costs. Limitations include laboratory-scale inefficiencies and the absence of comparative mechanical testing.

Source: JOM

DOI: 10.1007/s11837-026-08238-0

Authors: J. R. Chacón-Vargas, A. Esguerra-Arce, H. R. Sarmiento-Espinosa, J. Esguerra-Arce

Institutions: Escuela Colombiana de Ingenieria Julio Garavito, Universidad del Valle

Language: English

Topic: Environmental Impact and Sustainability

Subfield: Environmental Engineering

Field: Environmental Science

Domain: Physical Sciences

SDGs: Responsible consumption and production, Industry, innovation and infrastructure, Climate action

Open Access status: hybrid

Estimated APC paid: $3,790