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A Comparison between Powder Bed Fusion of Polyamide 12 and Aluminum Computer Numeric Control Machining: A Carbon Footprint and Energy Assessment

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  • Samuel Sipert

    (Centro Universitário SENAI CIMATEC, Av. Orlando Gomes, 1845 Piatã, Salvador 41650-010, BA, Brazil)

  • Edna dos Santos Almeida

    (Centro Universitário SENAI CIMATEC, Av. Orlando Gomes, 1845 Piatã, Salvador 41650-010, BA, Brazil)

  • Bruno Caetano dos Santos Silva

    (Centro Universitário SENAI CIMATEC, Av. Orlando Gomes, 1845 Piatã, Salvador 41650-010, BA, Brazil
    Instituto SENAI de Inovação em Conformação e União de Materiais, SENAI CIMATEC, Av. Orlando Gomes, 1845 Piatã, Salvador 41650-010, BA, Brazil)

  • Hamilton de Araújo Silva Neto

    (Centro Universitário SENAI CIMATEC, Av. Orlando Gomes, 1845 Piatã, Salvador 41650-010, BA, Brazil)

  • André Souza Oliveira

    (Centro Universitário SENAI CIMATEC, Av. Orlando Gomes, 1845 Piatã, Salvador 41650-010, BA, Brazil
    Instituto SENAI de Inovação em Conformação e União de Materiais, SENAI CIMATEC, Av. Orlando Gomes, 1845 Piatã, Salvador 41650-010, BA, Brazil)

  • Diego Russo Juliano

    (Shell Brasil Petróleo Ltd., Av. República do Chile, 330 Centro, Rio de Janeiro 20031-170, RJ, Brazil)

  • Rodrigo Santiago Coelho

    (Centro Universitário SENAI CIMATEC, Av. Orlando Gomes, 1845 Piatã, Salvador 41650-010, BA, Brazil
    Instituto SENAI de Inovação em Conformação e União de Materiais, SENAI CIMATEC, Av. Orlando Gomes, 1845 Piatã, Salvador 41650-010, BA, Brazil)

Abstract

This study presents a comparative life cycle assessment (LCA) of two manufacturing scenarios for a camera housing: Powder Bed Fusion (PBF) using polyamide 12 (PA-12) and Computer Numeric Control (CNC) machining using aluminum, for a cradle-to-gate boundary. The selected impact categories were cumulative energy demand (CED) and global warming potential (GWP). The key findings indicate that the PA-12 PBF part outperformed the aluminum CNC machining one in terms of environmental and energy performance, showing a significant reduction of approximately 90% in equivalent carbon emissions and 84% in cumulative energy demand. Sensitivity analyses revealed that the PBF process was highly sensitive to changes in the proportion of virgin/recycled material for the printing process, variations in the life cycle inventory (LCI) data sources for PA-12 powder production, and changes in the transportation system for imported materials, as is the case for the main input in the process (PA-12 powder). Sensitivity analysis also showed less impact for the PBF camera housing even considering a lifespan of one-fifth that of the aluminum for the impact categories considered. However, it should be noted that this analysis did not include considerations for the usage and end-of-life phases, which may have significant contributions to the overall environmental impact.

Suggested Citation

  • Samuel Sipert & Edna dos Santos Almeida & Bruno Caetano dos Santos Silva & Hamilton de Araújo Silva Neto & André Souza Oliveira & Diego Russo Juliano & Rodrigo Santiago Coelho, 2024. "A Comparison between Powder Bed Fusion of Polyamide 12 and Aluminum Computer Numeric Control Machining: A Carbon Footprint and Energy Assessment," Sustainability, MDPI, vol. 16(9), pages 1-16, April.
    • Handle: RePEc:gam:jsusta:v:16:y:2024:i:9:p:3767-:d:1386981
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    References listed on IDEAS

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    1. Samruddha Kokare & Radu Godina & João Pedro Oliveira, 2023. "Life Cycle Inventory of Additive Manufacturing Processes: A Review," Springer Proceedings in Business and Economics, in: João Carlos de Oliveira Matias & Carina Maria Oliveira Pimentel & João Carlos Gonçalves dos Reis & J (ed.), Quality Innovation and Sustainability, pages 77-86, Springer.
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