Handbook of Sustainability in Additive Manufacturing: Volume 1 (Environmental Footprints and Eco-design of Products and Processes)

This book highlights the sustainability aspects of additive manufacturing (AM) in two separate volumes. It describes the details of this technology and its implications on the entire product life cycle sustainability, as well as embedded carbon and the further research needed to move this technology towards sustainable, mainstream production. Sustainability is not new for any area of industry, including additive manufacturing, and there are currently a number of ongoing research projects, both in industry and in academic institutions, that are investigating sustainability, embedded carbon and research activities which would need to be done in the future to move this technology towards sustainable mainstream production. Contents 6 Introduction 7 1 What is Additive Manufacturing? 7 References 11 Sustainable Impact Evaluation of Support Structures in the Production of Extrusion-Based Parts 12 Abstract 12 1 Introduction 13 2 Additive Manufacturing 15 2.1 Material Extrusion 16 2.2 Powder Bed Fusion 18 2.3 Vat Photopolymerization 19 2.4 Material Jetting 20 2.5 Binder Jetting 20 2.6 Sheet Lamination 21 2.7 Directed Energy Deposition 21 3 Case Study 22 3.1 Relationship Between Dissolution Time and Material Volume 23 3.2 Super Rugby Trophy 2015 and Klein Bottle 27 4 Conclusions 31 References 32 A New Variant of Genetic Programming in Formulation of Laser Energy Consumption Model of 3D Printing Process 36 Abstract 36 1 Introduction 37 2 Experiment Details for the SLS Process in the Measurement of Laser Energy Consumption and TAS 41 3 Evolutionary Algorithms 43 3.1 Complexity-Based Evolutionary Approach of Genetic Programming (CN-GP) 43 4 Results and Discussion 46 4.1 Statistical Validation of Energy Consumption Models Against the Experimental Data 46 4.2 Relationships Between Laser Energy Consumption and TAS and Inputs via Sensitivity and Parametric Analysis of the Best Model 49 5 Conclusions 50 References 53 3D Printing Sociocultural Sustainability 56 Abstract 56 1 Introduction 57 2 Creating Connections 59 3 Craft Discourse and Sustainability 61 4 Making Context 63 5 Digital Crafting 65 6 Creating Balance 67 7 Digital Adaptation 72 8 Conclusion 74 References 76 Additive Manufacturing and its Effect on Sustainable Design 78 Abstract 78 1 Introduction 79 1.1 Planned Obsolescence 80 1.2 Sustainable Design Approaches 81 1.2.1 Eco-design 82 1.2.2 Sustainable Design 82 1.2.3 Road-Map for Sustainable Product Development 84 1.2.4 Cyclic-Solar-Safe Principles 84 1.2.5 Framework for Strategic Sustainable Development 84 1.2.6 Cradle to Cradle 86 1.2.7 Circular Economy 86 2 Relationship Between Design Quality and Sustainability 87 3 Additive Manufacturing 89 3.1 Complexity for Free 90 3.2 Mass Customization 92 3.3 Freedom of Design 93 3.4 Sustainability of Additive Manufacturing Beyond Design Freedom 94 3.5 Speculations on the Impact of Additive Manufacturing 97 3.6 New Sustainability Challenges Associated with Additive Manufacturing 100 4 Conclusions 101 References 102 Sustainable Design for Additive Manufacturing Through Functionality Integration and Part Consolidation 105 Abstract 105 1 Introduction 106 2 AM Enabled Design Methods 108 2.1 Impact of AM on Conventional DTM 108 2.1.1 Design Considerations for Manufacturing 109 2.1.2 Design Considerations for Assembly 110 2.1.3 Design Considerations for Performance 111 2.2 AM-Related Design Method 111 2.2.1 Design Guidelines and Design Rules 112 2.2.2 Modified DTM for AM 113 2.2.3 Design for Additive Manufacturing 114 2.3 On-Going AM-Related Design Research on Sustainability 117 3 Sustainable Design Methodology for AM 118 3.1 General Design Flow 119 3.2 Functional Design 120 3.3 Design Optimization 126 3.4 Design Refinement 129 3.5 Environmental Impact Evaluation 130 4 Case Study 136 5 Summary 143 References 144 Redesigning Production Systems 149 Abstract 149 1 Introduction: Systems in Crisis 149 2 The Change Is Now 153 3 Global Connectivity, Drivers for Change and Opportunities for Change 154 4 Additive Manufacturing and Global Connectivity for Sustainable Design and Production 156 5 Supply Chain Management (SCM) Implications of 3D Printing 157 5.1 The Development Cycle 157 5.2 Inventory Management: Production and Distribution 158 5.3 Logistic Postponement 159 5.4 Management of Spare Parts 160 6 Humanitarian Logistic Case Study 161 7 Changing Consumer Relationships 163 8 Contraction and Convergence 165 9 New Patterns of Production 167 10 Conclusion 170 References 171 Front Matter....Pages i-v Introduction....Pages 1-5 Sustainable Impact Evaluation of Support Structures in the Production of Extrusion-Based Parts....Pages 7-30 A New Variant of Genetic Programming in Formulation of Laser Energy Consumption Model of 3D Printing Process....Pages 31-50 3D Printing Sociocultural Sustainability....Pages 51-72 Additive Manufacturing and its Effect on Sustainable Design....Pages 73-99 Sustainable Design for Additive Manufacturing Through Functionality Integration and Part Consolidation....Pages 101-144 Redesigning Production Systems....Pages 145-168