New Research shows a significant reduction in greenhouse gas emissions (GHG) when using metal binder jetting instead of traditional metal casting methods. The Additive Manufacturer Green Trade Association (AMGTA) has released the preliminary results of a life-cycle analysis study conducted by the Yale School of the Environment (YSE) in partnership with Desktop Metal and Trane Technologies. The study focused on comparing the environmental impact of metal binder jetting versus traditional metal casting for an industrial part, specifically a steel scroll chiller in an HVAC system.
The preliminary results of the study confirmed a dramatic 38% reduction in GHG emissions through the binder jetting process. This reduction is primarily driven by the reduced energy demand during the production phase. Kevin Klug, Lead Additive Manufacturing Engineer for Trane Technologies, emphasized the importance of these findings in overcoming the uncertainty surrounding the life cycle emissions of binder jetting. He stated that with the results of this study, Trane Technologies can now consider the cost, productivity, and environmental impact of additive manufacturing earlier in a product’s design cycle, when the potential benefits are highest.
The study also highlighted the significance of the manufacturing facility’s energy mix and whether sustainable means were used in the energy grid’s production. Previous findings have shown that the energy mix at the location of generation can have a significant impact on GHG emissions. Additionally, the study found that redesigning the scroll chiller for lightweighting using a lattice-type structure had negligible effects on GHG emissions. The study emphasized that the overall dimensions of the parts being produced and efficient use of print volumes played a more important role than lightweighting.
The study did recognize that the environmental impacts of source powder production for binder jetting were approximately twice that of casting steel. However, this increase represented only a small portion of overall GHG emissions and did not significantly affect the study’s overall findings. Overall, the study concluded that binder jetting produced a more sustainable part, primarily due to the significant reduction in GHG emissions from reduced energy demand when compared to traditional manufacturing methods.
Sherri Monroe, Executive Director of the AMGTA, highlighted the significance of these findings for the additive manufacturing industry and companies in the broader manufacturing sector looking for more sustainable production methods. The study helps quantify the reduced energy demand of binder jetting and provides insights into the negligible impact of lightweighting. She emphasized that this specific use case may not encompass all potential environmental benefits of lightweighting, which may be more evident in the use phase of the parts.
The adoption of binder jetting has contributed to the double-digit annual growth in additive manufacturing over the past decade. This growth has been driven by cost advantages, large-volume production capabilities, and the potential for sustainability gains. The release of these findings reinforces the importance of sustainable production methods in the manufacturing industry and sheds light on the environmental benefits that can be achieved through additive manufacturing practices.
(Read the original post at VoxelMatters)
