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Life Cycle Assessment and Cost Analysis of Additive Manufacturing Repair Processes in the Mold Industry

Author

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  • Joana R. Gouveia

    (INEGI—Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 4200-465 Porto, Portugal)

  • Sara M. Pinto

    (INEGI—Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 4200-465 Porto, Portugal)

  • Sara Campos

    (INEGI—Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 4200-465 Porto, Portugal)

  • João R. Matos

    (INEGI—Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 4200-465 Porto, Portugal)

  • João Sobral

    (INEGI—Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 4200-465 Porto, Portugal)

  • Sílvia Esteves

    (INEGI—Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 4200-465 Porto, Portugal)

  • Luís Oliveira

    (INEGI—Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Industrial, 4200-465 Porto, Portugal)

Abstract

There is a growing demand for data regarding the environmental and economic performance of additive manufacturing to establish the role of this technology in the future circular industrial economy. This paper provides a comparative analysis of direct energy deposition technology with conventional manufacturing, specifically iron casting, in the context of the repairing capabilities of the direct energy deposition system in a damaged glass bottle mold. Making use of already established methodologies for environmental and economic assessment, a life cycle assessment and a life cycle costing study was conducted on each scenario to provide a holistic perspective on the advantages and limitations of each system. With the gathered life cycle inventory, the main environmental impacts and life cycle costs were determined. The hybrid repairing scenario results show a reduction of the environmental impacts and life cycle costs by avoiding resource consumption in the production of a new mold, with underlying economic advantages identified beyond the calculated results. Through strategic integration based in life cycle approaches, it is concluded that direct energy deposition technology can play a key role in the sustainable development of tooling and manufacturing industries, especially in products with large dimensions, complex geometry, and customized design.

Suggested Citation

  • Joana R. Gouveia & Sara M. Pinto & Sara Campos & João R. Matos & João Sobral & Sílvia Esteves & Luís Oliveira, 2022. "Life Cycle Assessment and Cost Analysis of Additive Manufacturing Repair Processes in the Mold Industry," Sustainability, MDPI, vol. 14(4), pages 1-17, February.
    • Handle: RePEc:gam:jsusta:v:14:y:2022:i:4:p:2105-:d:747916
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    References listed on IDEAS

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    1. Frank Walachowicz & Ingo Bernsdorf & Ulrike Papenfuss & Christine Zeller & Andreas Graichen & Vladimir Navrotsky & Noorie Rajvanshi & Christoph Kiener, 2017. "Comparative Energy, Resource and Recycling Lifecycle Analysis of the Industrial Repair Process of Gas Turbine Burners Using Conventional Machining and Additive Manufacturing," Journal of Industrial Ecology, Yale University, vol. 21(S1), pages 203-215, November.
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    1. Joana R. Gouveia & Sara M. Pinto & Sara Campos & João R. Matos & Catarina Costa & Thiago Assis Dutra & Sílvia Esteves & Luís Oliveira, 2022. "Life Cycle Assessment of a Circularity Case Study Using Additive Manufacturing," Sustainability, MDPI, vol. 14(15), pages 1-44, August.
    2. Asma Mecheter & Faris Tarlochan & Murat Kucukvar, 2023. "A Review of Conventional versus Additive Manufacturing for Metals: Life-Cycle Environmental and Economic Analysis," Sustainability, MDPI, vol. 15(16), pages 1-29, August.
    3. Hossein Eskandari Sabzi & Pedro E. J. Rivera-Díaz-del-Castillo, 2023. "Sustainable Powder-Based Additive Manufacturing Technology," Sustainability, MDPI, vol. 15(20), pages 1-15, October.
    4. Mario Santiago-Herrera & Jesús Ibáñez & Marco De Pamphilis & Jesús Manuel Alegre & Juan Antonio Tamayo-Ramos & Sonia Martel-Martín & Rocío Barros, 2023. "Comparative Life Cycle Assessment and Cost Analysis of the Production of Ti6Al4V-TiC Metal–Matrix Composite Powder by High-Energy Ball Milling and Ti6Al4V Powder by Gas Atomization," Sustainability, MDPI, vol. 15(8), pages 1-15, April.

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