{"id":10754,"date":"2017-10-17T08:55:18","date_gmt":"2017-10-17T08:55:18","guid":{"rendered":"http:\/\/federicofioretto.biz\/en\/?p=10754"},"modified":"2021-07-23T17:02:13","modified_gmt":"2021-07-23T17:02:13","slug":"sustainability-4-0-will-additive-manufacturing-make-it","status":"publish","type":"post","link":"https:\/\/federicofioretto.biz\/en\/sustainability-4-0-will-additive-manufacturing-make-it\/","title":{"rendered":"Sustainability 4.0: will Additive Manufacturing make it?."},"content":{"rendered":"<p>By Greta D&#8217;Angelo, PhD, and Federico Fioretto<\/p>\n<p><em>First of Two Articles<\/em><\/p>\n<p><strong>Sustainability<\/strong> is at risk of becoming just the latest <strong>buzzword<\/strong> in the world of business if it\u2019s not a very practical way to run industries and transform the way in which production is made. This noble concept must instead be widely <strong>implemented<\/strong> and help <strong>transform<\/strong> the way in which we design, make, use and recycle stuff. To achieve such a bold objective sustainability must <strong>embed<\/strong> itself into <strong>every process<\/strong> of manufacturing industries. This means that it has to get along with technology\u2019s evolution and accompany it in the right direction.<\/p>\n<p>On the other hand, the very \u201ctrendy\u201d <strong>4.0 Industrial Revolution<\/strong> will not be a \u201crevolution\u201d at all if it does not integrate Sustainability into its core strategic elements. In that case it would just be \u201c<strong>more of Industry 2.0<\/strong>\u201d at best. <strong>Sustainability<\/strong>, as our readers know well, must stand upon the three legs of <strong>environmental stewardship<\/strong>, <strong>economic prosperity<\/strong> and <strong>social value<\/strong> creation. Therefore we will seek to identify such features into a typical Industry 4.0 technology: <strong>Additive Manufacturing (AM)<\/strong>. Our aim is to help steer future developments of the technology in the right direction to boost sustainability of manufacturing and help Companies focus their <strong>investments<\/strong> towards the <strong>new industrial paradigm<\/strong>.<\/p>\n<p>During the past few years we have heard a lot about this rising technology, more commonly known as <strong>3D printing<\/strong>. This is deemed to become one of the technologies of the future and it is one of the <strong>macro trends<\/strong> of the Industry 4.0. While its potential unveils and the technology continues to develop, it is fundamental to identify and understand the <strong>relevant <\/strong><strong>environmental impacts<\/strong> in order to grasp AM\u2019s potential for a more <strong>sustainable industrial production<\/strong>. How AM will enable this is still unclear. Many of the studies are still focusing on material and energy consumption, which do not give a clear overview of the <strong>whole life cycle<\/strong> of the products made. However AM offers some <strong>resource efficiency<\/strong> benefits that, added to some specific design and production peculiarities leading to <strong>improved performance<\/strong>, have economic and environmental benefits.<\/p>\n<p>We\u2019ll leave aside for the moment the social value creation issue, which pertains more to the whole business and economic model than to the single production technology. Our <strong>focus<\/strong> will be on the <strong>environmental<\/strong> and <strong>economic<\/strong> <strong>impacts<\/strong>. Therefore the questions that we\u2019ll ask is whether AM improves the environmental performance of a production process, e.g. reducing waste or energy consumption, and also the economic performance of the industry, with the generation of more wealth as an outcome. When it comes to AM and sustainability there are three main factors to take into account:<\/p>\n<ol>\n<li>The <strong>product<\/strong> itself, from design to performance<\/li>\n<li>The <strong>production process<\/strong>, with its input-output balance<\/li>\n<li>The <strong>supply chain<\/strong>, from product order to delivery<\/li>\n<\/ol>\n<p>We are aware that the above subdivision is a bit artificial and that it is not possible to disentangle completely, for instance, the product from the production process. Nonetheless, we prefer to deal with the chosen issue in this way for clarity reasons. There will be some overlaps that the reader will, we hope, forgive. The first <strong>two points<\/strong> will be discussed <strong>here<\/strong>, in Part I of this article, whilst the <strong>last one <\/strong>will be discussed in <strong>Part II<\/strong> together with an overview of <strong>potential business models<\/strong> for the integration of AM in the production.<\/p>\n<ol>\n<li><strong>The Product itself <\/strong>\n<ul>\n<li>It is widely accepted in the industrial world that <strong>designing<\/strong> products today needs to be a process taking into account awareness of many very <strong>different factors<\/strong> and <strong>stakeholders<\/strong>. Design <strong>impacts<\/strong> the whole <strong>value chain<\/strong>. Due to its additive nature, the combined capacity of <strong>AM<\/strong> to make more complex objects with <strong>integrated functions<\/strong>, preference for using fewer parts and less production stages can <span style=\"font-weight: normal !msorm;\"><strong>reduce<\/strong><\/span> the <span style=\"font-weight: normal !msorm;\"><strong>material<\/strong><\/span> flow and consequently the environmental impact of the product.<\/li>\n<li>Points listed in 1.1 lead to a <strong>reduction<\/strong> of <strong>cost<\/strong> and <strong>increase<\/strong> of <strong>economic value<\/strong> even while making the same object, i.e. not considering smarter design allowed by the technology. Such improvements, of course, are <strong>larger<\/strong> when <strong>design<\/strong> is <strong>optimized<\/strong> for the technology.<\/li>\n<li>The capability to <strong>optimize geometries<\/strong> and create <strong>lightweight<\/strong> <strong>components<\/strong> also reduces material consumption adding to the reduction in material flow and cost cutting of the above points.<\/li>\n<li>The <strong>functional<\/strong><strong> design<\/strong> allowed by this manufacturing process can lead to products with <strong>better performance<\/strong>. For example, a recent study from the Technical University of Denmark, published on <strong><em>Nature<\/em><\/strong>, demonstrated that <strong>bone-inspired<\/strong> <strong>structures<\/strong> applied to the <strong>wing<\/strong> of an <strong>aircraft<\/strong> can lead to better mechanical properties and up to <strong>200 tons of fuel saved<\/strong> per year.<\/li>\n<li>The additive nature of the technology and the <strong>rise<\/strong> of <strong>hybrid processes<\/strong> (additive + subtractive), i.e. <strong>Lasertec 65 3D hybrid<\/strong> from DMG MORI, encourage the use of AM for <strong>repair practice<\/strong>. This <strong>improv<\/strong><strong>es<\/strong> the <strong>environmental<\/strong> <strong>impact<\/strong> of products by <strong>extending their life cycles<\/strong> and lowering the energy and resources required for the manufacturing of brand new products.<\/li>\n<li>The possibility of strict <strong>adherence<\/strong> to the individual <strong>customer\u2019s needs<\/strong> with one-off productions at <strong>affordable costs<\/strong> can deliver excellent <strong>customer experience<\/strong> and performance, combined with the <strong>cost saving<\/strong> aspects discussed above. As an example, a full <strong>inventory<\/strong> of <strong>spare parts<\/strong> for machinery in a <strong>remote location<\/strong> would be unbearably costly, but the possibility to <strong>produce <\/strong><strong>by AM<\/strong> the required parts at the moment of need makes a <strong>huge advantage<\/strong>, if not a possibility previously denied. The same principle can allow the production of objects specifically designed to fit a particular <strong>context<\/strong> or customers at a reasonable cost, something <strong>unthinkable<\/strong> with other processes, i.e. in the case of <strong>prosthetics<\/strong> and <strong>surgical implants<\/strong>.<\/li>\n<\/ul>\n<\/li>\n<li><strong>Production process<\/strong>, inputs-outputs balance:\n<ul>\n<li>A <strong>variety<\/strong> of <strong>materials<\/strong> are being used in AM, from polymers to metals, whose form is dependent on the type of process in use. The <strong>majority<\/strong> of <strong>polymers<\/strong> can be <strong>recycled<\/strong>, e. parts made of <strong>Fused Deposition Modelling<\/strong> (FDM) can be <strong>re-melted <\/strong>and turned into new filament by using a <strong>scrap-to-filament <\/strong>converter device. For <strong>metals<\/strong> instead, it is estimated that <strong>90 to 95 percent<\/strong>\u00a0of the <strong>leftover<\/strong> <strong>powders<\/strong> used in-process can be <strong>re-used<\/strong> in the following productions.<\/li>\n<li>AM allows to <strong>tackle<\/strong> one of the major problem of our planet:<strong> plastic waste<\/strong> in oceans and landfills. Numerous <span style=\"font-weight: normal !msorm;\"><strong>companies<\/strong><\/span>, i.e. Adidas to name one, started promoting many initiatives to <span style=\"font-weight: normal !msorm;\"><strong>collect<\/strong><\/span> the waste plastic and <span style=\"font-weight: normal !msorm;\"><strong>turn<\/strong><\/span> it into <span style=\"font-weight: normal !msorm;\"><strong>new products<\/strong><\/span>. Other initiatives are: Reflow and 3D-reprinter.<\/li>\n<li><b>Amid all these positive <\/b>aspects of AM regarding S<b>ustainability, it is to be mentioned that <\/b><span style=\"font-weight: normal !msorm;\"><strong>T<\/strong><\/span><span style=\"font-weight: normal !msorm;\"><strong>oxicological<\/strong><\/span> and <span style=\"font-weight: normal !msorm;\"><strong>environmental<\/strong><\/span> <span style=\"font-weight: normal !msorm;\"><strong>hazards<\/strong><\/span> from AM materials is an area that requires <span style=\"font-weight: normal !msorm;\"><strong>more<\/strong><\/span> <span style=\"font-weight: normal !msorm;\"><strong>research<\/strong><\/span> as it is not sufficiently understood at the moment. A number of studies reported the emission of <span style=\"font-weight: normal !msorm;\"><strong>harmful<\/strong><\/span> particles during the melting of ABS plastic, in desktop FDM printers. Liquid resins are also known to be <span style=\"font-weight: normal !msorm;\"><strong>mildly toxic<\/strong><\/span> and therefore their use is <span style=\"font-weight: normal !msorm;\"><strong>discouraged<\/strong><\/span> in <span style=\"font-weight: normal !msorm;\"><strong>non-ventilated<\/strong><\/span><\/li>\n<li>As a consequence of point 1.3 and 1.4, as in design of <span style=\"font-weight: normal !msorm;\"><strong>multi-component<\/strong><\/span><span style=\"font-weight: normal !msorm;\"><strong> objects<\/strong><\/span>, there is a <span style=\"font-weight: normal !msorm;\"><strong>simpler<\/strong><\/span> <span style=\"font-weight: normal !msorm;\"><strong>integrated-assembly<\/strong><\/span> production with the consequent <span style=\"font-weight: normal !msorm;\"><strong>reduction<\/strong><\/span> of <span style=\"font-weight: normal !msorm;\"><strong>cost<\/strong><\/span> and quality risks of assembly of different components. A potential environmental advantage is to be evaluated, considering also the <span style=\"font-weight: normal !msorm;\"><strong>reduction<\/strong><\/span> of <span style=\"font-weight: normal !msorm;\"><strong>weight<\/strong><\/span> and <span style=\"font-weight: normal !msorm;\"><strong>volume<\/strong><\/span> of products due to <span style=\"font-weight: normal !msorm;\"><strong>improved<\/strong><\/span> <span style=\"font-weight: normal !msorm;\"><strong>strength-to-weight<\/strong><\/span> This will reflect in maybe minimal part on the product itself but its <span style=\"font-weight: normal !msorm;\"><strong>effect<\/strong><\/span> on the <span style=\"font-weight: normal !msorm;\"><strong>performance<\/strong><\/span> of <span style=\"font-weight: normal !msorm;\"><strong>objects<\/strong><\/span> down the value chain that are explored elsewhere in this article can be very significant (see point 1.4 for an example)<\/li>\n<li><strong>Logistics<\/strong> and <strong>transportation<\/strong> are another point where <strong>savings<\/strong> in <strong>energy<\/strong> inputs and emissions\/outputs become interesting part of the Sustainability outcomes, either by environmental and economic impact (this point will be discussed more in depth in part II).<\/li>\n<li><strong>Research<\/strong>, although not yet conclusive and generalizable, <strong>hints<\/strong> to a <strong>better energy performance<\/strong> of AM compared to other production processes, something which has both an <strong>economic<\/strong> and an <strong>environmental<\/strong> <strong>impact<\/strong>. However, from a study of the University of California Berkeley, fellow researchers stated that \u201cit <strong>cannot be categorically stated<\/strong> that 3D printing (AM) is more <strong>environmentally friendly<\/strong> than machining or vice versa\u201d because the results are still <strong>dependent<\/strong> on <strong>many<\/strong> <strong>factors<\/strong>, for example: process and machine used, number of parts produced, process parameters and materials.<\/li>\n<\/ul>\n<\/li>\n<\/ol>\n<p>Already with the points highlighted above, there appears to be a <strong>remarkable<\/strong> <strong>value<\/strong> generated by the use of AM that <strong>can<\/strong> <strong>add<\/strong> to the <strong>Sustainability<\/strong> <strong>effort<\/strong> of <strong>manufacturing<\/strong> industries. To such value added, either in terms of cost saving\/increased profits and lower environmental impact, we can sum <strong>some advantages<\/strong> that can be ascribed to the <strong>social<\/strong>:<\/p>\n<ul>\n<li>The fact that <strong>customers<\/strong> can have a <strong>better product experience<\/strong> due to more personalized products is one;<\/li>\n<li>The possibility to <strong>reach distant<\/strong> or <strong>isolated<\/strong> <strong>customers<\/strong> with products or services that before AM were unthinkable;<\/li>\n<li>The <strong>empowerment<\/strong> of <strong>customers<\/strong> to become \u201c<strong>prosumers<\/strong>\u201d, i.e. consumers who produce themselves at least part of the goods they need. This is most likely one of the more <strong>dramatic changes<\/strong> that AM will produce in the way our <strong>economy<\/strong>, with its <strong>production<\/strong> and <strong>consumption<\/strong> <strong>models<\/strong> are;<\/li>\n<li>Finally, we believe that there are <strong>whole new possibilities<\/strong> of <strong>employment<\/strong> and <strong>business<\/strong>, even at a small <strong>entrepreneurial<\/strong> scale, stemming from the technology. This generation of distributed economic power and entrepreneurial capacity can deliver a <strong>high social value<\/strong>.<\/li>\n<\/ul>\n<p>In the <strong>second part <\/strong>of the article we will deal with the supply chain, including logistics aspects, and new business models to try to understand more wholly the potential of AM related to the three pillars of sustainability<\/p>\n<p>This two-part Article is intended to be a <strong>stimulus<\/strong> to the <strong>constructive<\/strong> <strong>discussion<\/strong> about the implications of emerging technologies on the future impact of manufacturing. All interested professionals in the area of Sustainability are <span style=\"font-weight: normal !msorm;\"><strong>welcome to comment<\/strong><\/span> and add value to the discussion by contacting the authors at IT@esinitiative.com.<\/p>\n<p>&nbsp;<\/p>\n<p><em><strong>Greta D\u2019Angelo<\/strong> is an industrial designer converted to the discipline of manufacturing engineering. She has a PhD in Additive Manufacturing from the Technology University of Denmark and has collaborated with numerous designers and universities, among which MIT and ETH Z\u00fcrich. Greta is now a consultant in the area of Digitalization and Additive Manufacturing for the development of sustainable business models.\u00a0<\/em><\/p>\n","protected":false},"excerpt":{"rendered":"<p>By Greta D&#8217;Angelo, PhD, and Federico Fioretto First of Two Articles Sustainability is at risk of becoming just the latest buzzword in the world of business<span class=\"excerpt-hellip\"> [\u2026]<\/span><\/p>\n","protected":false},"author":2,"featured_media":10755,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[137],"tags":[],"class_list":["post-10754","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Sustainability 4.0: will Additive Manufacturing make it?. - Federico Fioretto<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/federicofioretto.biz\/en\/sustainability-4-0-will-additive-manufacturing-make-it\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Sustainability 4.0: will Additive Manufacturing make it?. - 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