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Research Advances in Additive Manufacturing and Sustainable Industrial Engineering

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

Deadline for manuscript submissions: 30 June 2025 | Viewed by 12028

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Special Issue Editors

Dr. Francesco Tamburrino

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Guest Editor

Department of Civil and Industrial Engineering, Università di Pisa, 56126 Pisa, Italy
Interests: additive manufacturing (AM); industrial design; design and methods; AM post-processing; advanced materials technologies; polymer and metal lattice structures; cellular materials and dental materials
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Dr. Carlo Brondi

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Guest Editor

Institute of Intelligent Industrial Systems and Technologies for Advanced Manufacturing (CNR), 20133 Milano, Italy
Interests: production planning; process simulation; modeling; operations management; production; production management; optimization; sustainability metrics; integrated management systems; modular LCA assessment; industrial symbiosis; eco-design; technology substitution
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The enhancement of new industrial paradigms such as customization and functional design is increasingly pushing the development of additive manufacturing (AM) technologies. Additive manufacturing (AM) is a process in which a three-dimensional object is built from a computer-aided design (CAD) model, usually by successively processing materials in a layer-by-layer fashion. Additive technologies applied to manufacturing can provide a range of improved performances, such as lightweight design; topology optimization; the possibility of producing cellular and heterogeneous structures; metamaterial mechanisms; and embedded electronics and multi-material components.

From a different perspective, the rising issue of the sustainability of industrial systems and their ecological transition is pushing for the further development of existing technologies in compliance with future generations’ needs. To this end, a conceptual framework for AM development and its implementation in manufacturing product chains, with a focus on its impact on society, economy, and the environment, is necessary.

AM can promote sustainability by minimizing cost, waste, and inefficiency in manufacturing product chains. At the same time, specific issues such as energy consumption and material usage emerge when adapting such technologies to existing manufacturing chains, particularly in small batch production. A lack of methodologies, tools, and standards can in fact lead to adverse effects from a sustainability perspective.

The present Special Issue aims to explore the boundaries for the sustainable implementation of additive technologies within current manufacturing practices. More specifically, this Special Issue aims to present novel ideas, concepts, recent progress, and technical tools supporting the sustainable use of AM. Particular attention will be paid to the search for new conceptual frameworks that are able to clarify the boundaries and potential for the sustainable implementation of AM. Likewise, technical assessments and insights into specific applications are welcome. Submitted paper should provide a robust framework oriented towards both a representation of the AM technical potentialities and an analytical framework (i.e., LCC, LCA, S-LCA, MFA, etc.) to investigate sustainability-related aspects. AM application topics can range from a local perspective (i.e., the context of a green factory) to a broad application (i.e., the product life cycle perspective or technology replacement). Research articles and original reviews are welcome in this Special Issue. Topics for this Special Issue include, but are not limited to:

Advancement in AM technologies from a sustainability perspective;
Sustainable design of 3D components;
Sustainable materials for AM;
Lightweight AM structures;
AM post-processing;
Industrial ecology concepts applied to AM;
Resource efficiency via AM;
Life cycle assessment of 3D products or AM processes;
Value chain reconfiguration from a sustainability perspective;
Smart factories;
Technology replacement;
Simulation of 3D printing procedures;
Comparison between 3D products and traditional products;
AM scale-up;
Clean manufacturing via AM;
Standards related to sustainability of the industrial process;
Mechanical tests on AM components.

We look forward to receiving your contributions.

Dr. Francesco Tamburrino
Dr. Carlo Brondi
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
sustainability
industrial engineering
life cycle assessment
design for additive manufacturing
sustainable materials
post-processing of AM parts
sustainable design

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Published Papers (7 papers)

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Research

32 pages, 3964 KiB

Open AccessArticle

Facilitating the Production of 3D-Printed Spare Parts in the Design of Plastic Parts: A Design Requirement Review

by Alma van Oudheusden, Jeremy Faludi and Ruud Balkenende

Sustainability 2024, 16(21), 9203; https://doi.org/10.3390/su16219203 - 23 Oct 2024

Viewed by 763

Abstract

Using additive manufacturing for spare part production can ensure that spare parts are available for a long time. However, spare parts are currently not designed for additive manufacturing. This study aimed to find how the production of 3D-printed spare parts can be facilitated in the design of plastic parts. We used a literature review and illustrative case to find how the design requirements for standard injection moulded plastic parts relate to the manufacturing capabilities of additive manufacturing for spare parts. The design requirements were defined by assigning corresponding structural and material properties. These requirements were then used to construct and evaluate the capabilities of additive manufacturing compared to injection moulding. It was found that additive manufacturing is especially suitable for requirements like Accuracy, Heat resistance, and Chemical resistance. However, to fully enable 3D-printed spare parts, certain design challenges still need to be tackled. Designers should pay careful attention to the synergies and trade-offs between design requirements and the challenges that might arise from the combination of certain requirements. Also, designers should ensure products are easily reparable before considering 3D-printed spare parts. If we target these challenges in the design phase, we can facilitate 3D-printed spare parts that enable product repairability. Full article

(This article belongs to the Special Issue Research Advances in Additive Manufacturing and Sustainable Industrial Engineering)

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22 pages, 2573 KiB

Open AccessArticle

SAMSax—An Innovative Living Lab for the Advancement of a Circular Economy through Additive Manufacturing Technologies

by Adelina Berkemeier, Lisa Kühnel, Dominik Dürigen, Holger Hoffmann, Henning Zeidler, Angelika C. Bullinger and André Wagenführ

Sustainability 2024, 16(2), 823; https://doi.org/10.3390/su16020823 - 18 Jan 2024

Cited by 1 | Viewed by 1724

Abstract

The sustainable development of products is of great interest to both industry and consumers due to various factors, such as anthropogenic climate change and the scarcity of resources and materials. In response to this, the simul⁺ Living Lab Sustainable Additive Manufacturing in Saxony (SAMSax) has been established as a physical experimental space aimed at improving the sustainability of products. This includes selecting resource-efficient manufacturing processes, using renewable materials, reducing energy consumption during use, and designing for recyclability. The innovative approach of the lab also integrates an open innovation process, involving present and potential stakeholders. Collaborating closely with stakeholders from industry, academia, and government fosters idea generation, provides solution approaches, and enhances acceptance and practical implementation. Methodologically, SAMSax focuses on upcycling organic and inorganic residues as well as by-products from industry and agriculture, reintegrating them as innovative components in industrial production using additive manufacturing (“3D printing”). The Living Lab provides a space for networking and active knowledge transfer through digital technologies, analyses, and collaborative developments, enabling the testing and evaluation of innovations in a real-world environment. Several potential waste materials suitable for additive manufacturing and new products have already been identified. In addition to industrial residues, materials, such as paper and wood dust; industrial by-products, such as sand; and agricultural residues, like harvest residues, are being analyzed, processed, and tested using additive manufacturing in the laboratory. In this way, SAMSax can contribute to an integrated and consistent circular economy. The research aims to demonstrate that the SAMSax Living Lab is a crucial driver of innovation in the field of additive manufacturing. Furthermore, this study contributes by presenting the Living Lab as an application-oriented research environment, focusing on innovative implementation in small- and medium-sized enterprises. Full article

(This article belongs to the Special Issue Research Advances in Additive Manufacturing and Sustainable Industrial Engineering)

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14 pages, 3321 KiB

Open AccessArticle

EcoPrintAnalyzer: Assessing Sustainability in Material Extrusion Additive Manufacturing for Informed Decision-Making

by Beatrice Aruanno

Sustainability 2024, 16(2), 615; https://doi.org/10.3390/su16020615 - 10 Jan 2024

Cited by 1 | Viewed by 1121

Abstract

Sustainability is fundamental in the field of additive manufacturing (AM) for improving eco-consciousness and driving evolution toward environmentally responsible production methods. Compared to traditional manufacturing processes, AM technologies can be more resource-efficient and offer innovative solutions for creating eco-friendly processes and products. Nevertheless, there is significant potential for improvement in additive manufacturing sustainability. The key factors driving this improvement include design optimization and increased awareness. Designers and engineers can create designs that optimize material efficiency and reduce support structures. Raising awareness and educating stakeholders about the environmental benefits of AM can promote responsible choices throughout the industrial process. The development of a tool to assess the environmental impact of AM processes could be a significant contribution to advancing sustainability in the AM field. The EcoPrintAnalyzer, introduced as a complementary plugin for UltiMaker Cura, offers data on the equivalent carbon dioxide footprint and energy consumption in material extrusion additive manufacturing. This tool facilitates informed decision-making regarding materials, designs, and settings, enabling users to optimize their AM processes for reduced waste and enhanced energy efficiency. Beyond aiding decision-making, the EcoPrintAnalyzer fosters environmental consciousness and encourages the adoption of sustainable practices within the AM ecosystem. The efficacy of the tool is demonstrated through the 3DBenchy model case study, showcasing its intuitive interface and seamless integration within the AM process workflow for immediate and comparative environmental impact assessments across different process configurations. Full article

(This article belongs to the Special Issue Research Advances in Additive Manufacturing and Sustainable Industrial Engineering)

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14 pages, 2286 KiB

Open AccessArticle

Sustainability in Healthcare Sector: The Dental Aligners Case

by Chiara Caelli, Francesco Tamburrino, Carlo Brondi, Armando Viviano Razionale, Andrea Ballarino and Sandro Barone

Sustainability 2023, 15(24), 16757; https://doi.org/10.3390/su152416757 - 12 Dec 2023

Cited by 1 | Viewed by 1195

Abstract

Additive manufacturing is a technology gaining ground in fields where a high degree of product customization is required; in particular, several aspects need to be explored concerning traditional technologies, such as the variety of materials and their consumption. It also remains to be clarified whether these technologies can contribute to the ecological transition when applied in healthcare. This study compares two technologies for producing clear dental aligners: thermoforming and direct 3D printing. The former method thermoforms a polymeric disc over 3D-printed, customized models. The second, more innovative approach involves directly printing aligners using Additive Manufacturing (AM), specifically applying Digital Light Processing (DLP) technology. The study conducts a comparative Life Cycle Assessment (LCA) analysis to assess the environmental impact of these two different manufacturing processes. The research results highlight that adopting direct printing through AM can bring advantages in terms of environmental sustainability, thanks to the reduction in raw materials and electricity consumption. These drops are drivers for the decreased potential environmental impacts across all impact categories considered within the EF 3.1 method. Furthermore, lowering the amount of raw material needed in the direct printing process contributes to a notable decrease in the overall volume of waste generated, emphasizing the environmental benefits of this technique. Full article

(This article belongs to the Special Issue Research Advances in Additive Manufacturing and Sustainable Industrial Engineering)

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21 pages, 9848 KiB

Open AccessArticle

Features and Sustainable Design of Firefighting Safety Footwear for Fire Extinguishing and Rescue Operations

by Marianna Tomaskova and Jozef Krajňák

Sustainability 2023, 15(20), 15108; https://doi.org/10.3390/su152015108 - 20 Oct 2023

Cited by 1 | Viewed by 1827

Abstract

Firefighters are regularly exposed to risk of injuries as a result of their intervention activities connected with hazards from fire and explosion, as well as due to carrying heavy personal working equipment and injured victims from accidents. Another hazardous factor is working under unfavorable weather conditions and also moving on slippery or bumpy surfaces. Employers provide personal protective work equipment to employees if a hazard cannot be eliminated or reduced by technical means, such as means of collective protection or methods and forms of work organization. Personal Protective Equipment (PPE) should provide effective protection against existing and foreseeable hazards and should not in itself create a greater risk. It should be adapted to the existing and predictable working conditions and working environment at the work site, meet the criteria of ergonomics and the health condition of an employee as well as be suitable and adapted to the wearer’s body so that, if possible, there is no risk of harm to the employee’s health. The aim of this Special Issue is to explore the limits of sustainable implementation of additive technologies within current manufacturing practices and current requirements for personal protective equipment for firefighters. More precisely, the goal of this special article is to show new ideas in firefighting footwear such as a quick donning and doffing system as well as various other improvements and sustainable design of firefighting footwear. The aim is to present new ideas and concepts, the latest advances, and technical tools supporting the sustainable use of protective firefighting footwear. Special attention will be paid to standards that ensure the highest standard and quality. Full article

(This article belongs to the Special Issue Research Advances in Additive Manufacturing and Sustainable Industrial Engineering)

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14 pages, 2280 KiB

Open AccessArticle

Environmental Impact Assessment of Different Manufacturing Technologies Oriented to Architectonic Recovery and Conservation of Cultural Heritage

by Alessio Altadonna, Filippo Cucinotta, Marcello Raffaele, Fabio Salmeri and Felice Sfravara

Sustainability 2023, 15(18), 13487; https://doi.org/10.3390/su151813487 - 8 Sep 2023

Cited by 3 | Viewed by 1730

Abstract

Our cultural society has made remarkable advancements in creating digital models that depict the built environment, landscape, and reality. The advent of technologies such as terrestrial laser scanning and drone-based photogrammetry, coupled with sophisticated software capable of processing hundreds of photographs to generate point clouds, has elevated the significance of three-dimensional surveying in documentation and restoration. Point cloud processing and modeling software enable the creation of precise digital replicas of the investigated architecture, which can be scaled down and transformed into physically identical models. Through the export of STL files and the utilization of both subtractive and additive 3D printing technologies, tactile models resembling traditional manually crafted plastics can be obtained. An exemplary study focuses on the Gothic church of Santa Maria Alemanna in Messina, Italy, where laser scanner surveys and 3D prints using various technologies were applied to different parts of the building. The models were produced using a CNC milling machine and a 3D printer for fused deposition modeling. The sustainability of these production technologies was assessed through a Life Cycle Assessment, demonstrating the environmental advantages of additive manufacturing, including the use of materials with high recyclability and lower energy consumption. Additionally, the additive approach helps reduce processing waste. Full article

(This article belongs to the Special Issue Research Advances in Additive Manufacturing and Sustainable Industrial Engineering)

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19 pages, 10980 KiB

Open AccessArticle

Multi-Material Additive Manufacturing: Creating IN718-AISI 316L Bimetallic Parts by 3D Printing, Debinding, and Sintering

by Paolo Ferro, Alberto Fabrizi, Hamada Elsayed and Gianpaolo Savio

Sustainability 2023, 15(15), 11911; https://doi.org/10.3390/su151511911 - 2 Aug 2023

Cited by 7 | Viewed by 2193

Abstract

Allowing for complex shape and low energy consumption, 3D printing, debinding, and sintering (PDS) is a promising and cost-effective additive manufacturing (AM) technology. Moreover, PDS is particularly suitable for producing bimetallic parts using two metal/polymer composite filaments in the same nozzle, known as co-extrusion, or in different nozzles, in a setup called bi-extrusion. The paper describes a first attempt to produce bimetallic parts using Inconel 718 and AISI 316L stainless steel via PDS. The primary goal is to assess the metallurgical characteristics, part shrinkage, relative density, and the interdiffusion phenomenon occurring at the interface of the two alloys. A first set of experiments was conducted to investigate the effect of deposition patterns on the above-mentioned features while keeping the same binding and sintering heat treatment. Different sintering temperatures (1260 °C, 1300 °C, and 1350 °C) and holding times (4 h and 8 h) were then investigated to improve the density of the printed parts. Co-extruded parts showed a better dimensional stability against the variations induced by the binding and sintering heat treatment, compared to bi-extruded samples. In co-extruded parts, shrinkage depends on scanning strategy; moreover, the higher the temperature and holding time of the sintering heat treatment, the higher the density reached. The work expands the knowledge of PDS for metallic multi-materials, opening new possibilities for designing and utilizing functionally graded materials in optimized components. With the ability to create intricate geometries and lightweight structures, PDS enables energy savings across industries, such as the aerospace and automotive industries, by reducing component weight and enhancing fuel efficiency. Furthermore, PDS offers substantial advantages in terms of resource efficiency, waste reduction, and energy consumption compared to other metal AM technologies, thereby reducing environmental impact. Full article

(This article belongs to the Special Issue Research Advances in Additive Manufacturing and Sustainable Industrial Engineering)

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