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Sustainability of Additive Manufacturing and 3D-Printed Parts
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Sustainability of Additive Manufacturing and 3D-Printed Parts

A special issue of Sustainability (ISSN 2071-1050). This special issue belongs to the section "Sustainable Engineering and Science".

Deadline for manuscript submissions: closed (26 March 2023) | Viewed by 36102

Special Issue Editors

Dr. Mohammad Reza Khosravani

E-Mail Website
Guest Editor
Department of Mechanical Engineering, University of Siegen, 57068 Siegen, Germany
Interests: fracture mechanics; composite materials; 3D printing, material behaviour; experimental tests
Dr. Payam Soltani

E-Mail Website
Guest Editor
School of Engineering and the Built Environment, Birmingham City University, Birmingham, UK
Interests: smart materials and structures; simulation; nonlinear dynamics; energy harvesting; vibration absorbers
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM), also known as three-dimensional (3D) printing, has been drawing significant interest in recent years. AM has proven its unique and favourable abilities in the fabrication of geometrically complex components. Initially, AM was utilised for prototyping, but currently, it is being used in the rapid manufacturing of final products. Although AM has progressed significantly in recent years, there are several engineering aspects which need further investigations. 3D printing technology can reduce production cost and increase supply chain efficiency. Moreover, it has the potential to become a more sustainable method in comparison to other traditional methods of manufacturing. In this context, various related aspects must be investigated carefully to demonstrate and prove the sustainability of this manufacturing process. More in depth, reduction in waste material and energy consumption, utilising sustainable materials, and environmental effects are examples of the issues that must be considered and properly addressed.

The main focus of this Special Issue will therefore be assessing the different aspects of 3D printing technology in general, along with detailed discussion on the sustainability of its different aspects. In detail, this Special Issue aims at representing novel ideas, recent progresses, and technical details in regard to the structural integrity of 3D-printed components with specific emphasis on sustainability, material selection, design principals, experimental practice, numerical simulation, optimisation, and qualification. Topics for this Special Issue include but are not limited to:

  • Advances in AM processes;
  • Simulation of 3D printing procedures;
  • AM scale up, quality control, and economics;
  • Clean manufacturing via 3D printing technology;
  • Standards and qualification of 3D-printed components;
  • Mechanical tests and simulation of 3D-printed components.

Dr. Mohammad Reza Khosravani
Dr. Payam Soltani
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Sustainability is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • 3D-printed materials
  • recycled materials
  • optimisation
  • sustainability

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Published Papers (6 papers)

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Research

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33 pages, 5955 KiB  
Article
3D Printing for Repair: An Approach for Enhancing Repair
by Alma van Oudheusden, Julieta Bolaños Arriola, Jeremy Faludi, Bas Flipsen and Ruud Balkenende
Sustainability 2023, 15(6), 5168; https://doi.org/10.3390/su15065168 - 14 Mar 2023
Cited by 5 | Viewed by 3985
Abstract
The availability and storage of spare parts are the main barriers to product repair. One possibility would be to 3D print spare parts, which would also enable the repair of products not intended to be repaired. Besides manufacturers, 3D printing spare parts is [...] Read more.
The availability and storage of spare parts are the main barriers to product repair. One possibility would be to 3D print spare parts, which would also enable the repair of products not intended to be repaired. Besides manufacturers, 3D printing spare parts is an interesting option for self-repair by consumers. However, the digitisation of spare parts for 3D printing is a challenge. There is little guidance on how to make a 3D-printed version of the original part. This paper establishes a framework through a literature review and experimental study to describe how to use 3D printing to produce spare parts for repair. Additionally, qualitative data coding was used to find the influence of previous experience, process implementation, and part complexity on the overall success of the 3D printing for repair (3DPfR) process. Our study showed that the 3DPfR process can be described as an iterative design for an additive manufacturing process that is integrated into a repair process. Additionally, it was found that the incorrect implementation of process steps was the most important predictor of the repair result. The steps that were performed incorrectly the most were synthesising design concepts (64%) and validating print quality (also 64%). Full article
(This article belongs to the Special Issue Sustainability of Additive Manufacturing and 3D-Printed Parts)
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30 pages, 7025 KiB  
Article
Large-Scale Automated Additive Construction: Overview, Robotic Solutions, Sustainability, and Future Prospect
by Mohammad Reza Khosravani and Azadeh Haghighi
Sustainability 2022, 14(15), 9782; https://doi.org/10.3390/su14159782 - 8 Aug 2022
Cited by 34 | Viewed by 5128
Abstract
Additive manufacturing has drawn significant attention in both academia and industry due to its capabilities and promising potential in various sectors. However, the adoption of this technology in large-scale construction is still limited due to the numerous existing challenges. In this work, a [...] Read more.
Additive manufacturing has drawn significant attention in both academia and industry due to its capabilities and promising potential in various sectors. However, the adoption of this technology in large-scale construction is still limited due to the numerous existing challenges. In this work, a comprehensive review of large-scale automated additive construction, its challenges, and emerging advances with a focus on robotic solutions and environmental sustainability is presented. The potential interrelations of the two topics are also discussed. A new classification scheme of available and emerging robotic solutions in automated additive construction is presented. Moreover, the vision of environmental sustainability is explored through three lenses: process, material, and printed large-scale structures/buildings. Finally, the current challenges and potential future directions are highlighted. The provided state of the art and challenges can be used as a guideline for future research on large-scale automated additive construction. Full article
(This article belongs to the Special Issue Sustainability of Additive Manufacturing and 3D-Printed Parts)
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26 pages, 3112 KiB  
Article
Facilitating Safe FFF 3D Printing: A Prototype Material Case Study
by Panagiotis Karayannis, Stratos Saliakas, Ioannis Kokkinopoulos, Spyridon Damilos, Elias P. Koumoulos, Eleni Gkartzou, Julio Gomez and Constantinos Charitidis
Sustainability 2022, 14(5), 3046; https://doi.org/10.3390/su14053046 - 4 Mar 2022
Cited by 5 | Viewed by 4593
Abstract
Three-dimensional (3D) printing has introduced a paradigm shift in the manufacturing world, and it is increasing in popularity. In cases of such rapid and widespread acceptance of novel technologies, material or process safety issues may be underestimated, due to safety research being outpaced [...] Read more.
Three-dimensional (3D) printing has introduced a paradigm shift in the manufacturing world, and it is increasing in popularity. In cases of such rapid and widespread acceptance of novel technologies, material or process safety issues may be underestimated, due to safety research being outpaced by the breakthroughs of innovation. However, a definitive approach in studying the various occupational or environmental risks of new technologies is a vital part of their sustainable application. In fused filament fabrication (FFF) 3D printing, the practicality and simplicity of the method are juxtaposed by ultrafine particle (UFP) and volatile organic compound (VOC) emission hazards. In this work, the decision of selecting the optimal material for the mass production of a microfluidic device substrate via FFF 3D printing is supported by an emission/exposure assessment. Three candidate prototype materials are evaluated in terms of their comparative emission potential. The impact of nozzle temperature settings, as well as the microfluidic device’s structural characteristics regarding the magnitude of emissions, is evaluated. The projected exposure of the employees operating the 3D printer is determined. The concept behind this series of experiments is proposed as a methodology to generate an additional set of decision-support decision-making criteria for FFF 3D printing production cases. Full article
(This article belongs to the Special Issue Sustainability of Additive Manufacturing and 3D-Printed Parts)
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17 pages, 3863 KiB  
Article
A Holistic View on Sustainability in Additive and Subtractive Manufacturing: A Comparative Empirical Study of Eyewear Production Systems
by Sam Solaimani, Alireza Parandian and Nabi Nabiollahi
Sustainability 2021, 13(19), 10775; https://doi.org/10.3390/su131910775 - 28 Sep 2021
Cited by 10 | Viewed by 4804
Abstract
To achieve sustainability across the product life cycle, attention to the production process is a prerequisite. As a result of technological advancements, innovation and inventions in production methods are in full swing. Production methods that enable mass customisation (MC) are one of the [...] Read more.
To achieve sustainability across the product life cycle, attention to the production process is a prerequisite. As a result of technological advancements, innovation and inventions in production methods are in full swing. Production methods that enable mass customisation (MC) are one of the recent developments in the production domain. This study aims to empirically explore the sustainability impact of two MC-oriented production methods, namely, additive manufacturing (i.e., Selective Laser Sintering) and subtractive manufacturing (Computer Numerical Control Milling) within two complete production lines (i.e., from raw material to assembly) for a wearable product. In the context of the triple bottom line framework, the production lines are analysed from an economic, environmental, and social standpoint. A Discrete-Event Simulation (DES) is used to quantify and compare both production systems with their inherent variability in a dynamic setting of fluctuating order volume and diversity. The findings of the simulation are qualitatively evaluated using expert interviews. This study provides a detailed insight into several sustainability trade-offs in production systems where additive and subtractive manufacturing are involved. Full article
(This article belongs to the Special Issue Sustainability of Additive Manufacturing and 3D-Printed Parts)
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Review

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14 pages, 1345 KiB  
Review
A Review on the Application of 3D Printing Technology in Pavement Maintenance
by Fangyuan Gong, Xuejiao Cheng, Qinghua Wang, Yi Chen, Zhanping You and Yu Liu
Sustainability 2023, 15(7), 6237; https://doi.org/10.3390/su15076237 - 5 Apr 2023
Cited by 6 | Viewed by 3321
Abstract
To examine the application and significance of 3D printing technology in pavement maintenance engineering, a review of the current developments in principles, types, materials, and equipment for 3D printing was conducted. A comparison and analysis of traditional methods and 3D printing for asphalt [...] Read more.
To examine the application and significance of 3D printing technology in pavement maintenance engineering, a review of the current developments in principles, types, materials, and equipment for 3D printing was conducted. A comparison and analysis of traditional methods and 3D printing for asphalt pavement maintenance led to an investigation of 3D asphalt printing technologies and equipment. As a result, the following suggestions and conclusions are proposed: 3D printing technology can increase the level of automation and standardization of pavement maintenance engineering, leading to effective improvements in worker safety, climate adaptability, repair accuracy, etc. For on-site repair of cracks and minor potholes, utilizing material extrusion technology a mobile 3D asphalt printing robot with a screw extrusion device can be used for accuracy and flexibility. For efficient repair of varying cracks, material jetting technology with a UAV equipped with a 3D printing air-feeding device can be employed. Full article
(This article belongs to the Special Issue Sustainability of Additive Manufacturing and 3D-Printed Parts)
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22 pages, 8457 KiB  
Review
Design for Additive Manufacturing: A Systematic Review
by Abdullah Alfaify, Mustafa Saleh, Fawaz M. Abdullah and Abdulrahman M. Al-Ahmari
Sustainability 2020, 12(19), 7936; https://doi.org/10.3390/su12197936 - 25 Sep 2020
Cited by 104 | Viewed by 12773
Abstract
The last few decades have seen rapid growth in additive manufacturing (AM) technologies. AM has implemented a novel method of production in design, manufacture, and delivery to end-users. Accordingly, AM technologies have given great flexibility in design for building complex components, highly customized [...] Read more.
The last few decades have seen rapid growth in additive manufacturing (AM) technologies. AM has implemented a novel method of production in design, manufacture, and delivery to end-users. Accordingly, AM technologies have given great flexibility in design for building complex components, highly customized products, effective waste minimization, high material variety, and sustainable products. This review paper addresses the evolution of engineering design to take advantage of the opportunities provided by AM and its applications. It discusses issues related to the design of cellular and support structures, build orientation, part consolidation and assembly, materials, part complexity, and product sustainability. Full article
(This article belongs to the Special Issue Sustainability of Additive Manufacturing and 3D-Printed Parts)
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