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Thomas, Liji. "Is 3D Printing Really a Clean Technology?". AZoCleantech. https://www.azocleantech.com/article.aspx?ArticleID=908. (accessed September 28, 2024).

AZoCleantech interviews Carbon Limit's Founder and CEO about the company's mission to reduce one billion tons of CO2 with CaptureCrete, an innovative concrete technology.

Any new technology, however promising, must be assessed for its environmental sustainability. This applies to 3D printing, also called additive manufacturing (AM), which is being developed as an alternative manufacturing technology in many fields of production. Clean technology is defined in terms of the lifecycle, greenhouse gas emissions, air pollution, toxic materials, and the use of non-renewable resources.

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Thomas, Liji. "Is 3D Printing Really a Clean Technology?". AZoCleantech. 28 September 2024. .

The downside is that the use of unlike materials in the same print cycle reduces recyclable potential. A potential green solution is to use more complex parts, avoiding the need for assembly and disassembly, as well as using one or a very few tunable materials to create a whole object.

Another concern is worker exposure to toxic materials with 3D printing, whether at home or in offices, largely due to the absence of safety measures that are routine in industrial situations.

Optimal printer design, with minimal support material, could also reduce waste generation markedly with certain technologies, but not all. For instance, inkjet and fused deposition modelling (FDM) are very low-waste processes.

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At present most 3D printing is carried out on a small scale. However, it is expanding quickly as tools and materials become more affordable, process quality improves, and innovative techniques emerge.

At present, injection molding is the most efficient production method for large runs covering hundreds of thousands of parts. Inkjet printing is the 3D printing method with the lowest operating costs due to its use of inexpensive open-source recipes, requiring only operator expertise.

Greenhouse gas emissions are likely to drop steadily if 3D printing replaces injection molding technology globally. However, with current technology, whether 3D printing could replace injection molding technology globally remains a question.

This application uses a wide range of energy, but through proper designs it can produce self-supporting part designs with low waste. It uses easily recycled plastics like polyethylene terephthalate (PET), poorly recycled plastics like acrylonitrile butadiene styrene (ABS), and polylactic acid (PLA), which is biodegradable but requires special composting.

3D printed parts may also impart higher use-phase energy efficiency, such as by lessening the component weight in aerospace and transportation applications. Regenerative cooling and fuel efficiency could be optimized by designing complex engine parts for printing like combustion chamber walls containing fluid channels.

This uses a lot of energy except when batch printing. It is adapted to a wide range of materials including metals, ceramics, thermoplastics, and glass, though slightly less with batch printing. Residual powder can be reused, and support metals recycled, though the support plastic goes to landfill.

Thomas, Liji. (2020, February 17). Is 3D Printing Really a Clean Technology?. AZoCleantech. Retrieved on September 28, 2024 from https://www.azocleantech.com/article.aspx?ArticleID=908.

3D printing cannot typically be used to print a whole working object with multiple materials simultaneously. Instead, it produces simple components, to be assembled with other parts. However, experimental multi-material printers are already in existence, and if commercialized, could greatly increase the reach of 3D printing.

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A third option is using only biodegradable materials, including compostable wiring and incinerable plastics.  The environmental impact depends on the consumption of energy and material, which varies with technology, material and frequency of use.

The cleanest processes sometimes produce the lowest quality, however, and green materials for 3D printing like wood, sawdust and salt are often unavailable or unviable.

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Lean production is a huge advantage of 3D printing, since it eliminates warehousing and work-in-progress costs, and reduces any financial incentive to overproduce, unlike injection molding.

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The Thermo Scientific™ MAX-iAQ™ is a fully automated ambient air monitoring solution with 20 detection points, specifically designed for the accurate detection of trace compounds in environments with high humidity.

This technique uses materials like ceramics, plaster, sawdust, concrete, starch, salt and sugar. While it saves a lot of energy on batch printing and reduces waste, the large-scale printing of consumer goods is unviable.

Sustainable 3D printing demands optimization of the period of operation and part geometry.  In general, 3D printing is probably better for the environment compared to machining technologies, but injection molding production processes are superior at the same scale. A printer used for only a few hours each week will leave a larger footprint than when used continuously. 3D printing of hollow-core parts is cleaner than solid-block parts, but with machining, the reverse is true.

3D printing is ideal for legacy repair of single components of outdated machines like washing machines or bike parts. This keeps perfectly good machines in continued use, avoiding needless discards or replacement.

Thomas, Liji. 2020. Is 3D Printing Really a Clean Technology?. AZoCleantech, viewed 28 September 2024, https://www.azocleantech.com/article.aspx?ArticleID=908.

Dr. Liji Thomas is an OB-GYN, who graduated from the Government Medical College, University of Calicut, Kerala, in 2001. Liji practiced as a full-time consultant in obstetrics/gynecology in a private hospital for a few years following her graduation. She has counseled hundreds of patients facing issues from pregnancy-related problems and infertility, and has been in charge of over 2,000 deliveries, striving always to achieve a normal delivery rather than operative.

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Resource utilization is practically the same with 3D printing or injection molding. Transportation costs may be only marginally reduced, even with on-site printing, since feedstock shipping is still required. If a single producer were to offer multiple types of 3D printed parts of a single material on demand, only warehousing and shipping costs apply. Even so, this impacts manufacturing costs only slightly.

This process is capable of using multiple liquid polymers, with batch printing associated with high energy-efficiency. It uses more toxic raw materials (but with higher reusability value), often produces less waste, and requires minimal support material. The solidified polymer cannot be recycled.

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