Life cycle analysis for 3D printed PA11 and PA12 components

In detail

Over the last 30 years, additive manufacturing has developed from a prototyping method to an industrial manufacturing technology, thanks to increased productivity and process stability. Powder bed-based processes such as selective laser sintering (PBF-LB/P) and high-speed sintering (PBF-IR/P) enable the production of plastic parts from thermoplastic powders (e.g. PA11, PA12, SLS used powder) with properties similar to those of injection molding. The advantages are higher material efficiency, lighter components and local production, which protect the environment. However, a comprehensive assessment of the environmental impact of plastic-based 3D printing and the potential for greenhouse gas savings is lacking. The aim of the project is to assess the ecological impact of plastic-based 3D printing in order to determine the potential for greenhouse gas savings and to find out which companies and products can benefit from it.

First, the process chain of the selected 3D printing process is mapped. Subsequently, relevant conventional processes, such as injection molding, are identified and their process chains are presented. After that, the data required to determine the environmental impacts of powder-bed-based 3D printing for polymers and of the conventional process is defined and collected. The potential greenhouse gas savings that can be achieved by using 3D printing are then calculated. A sensitivity analysis identifies key influencing factors that impact greenhouse gas savings. Finally, recommendations for action are derived to use 3D printing in a targeted manner to reduce greenhouse gases.

• Modeling of 3D printing processes for polymers and their greenhouse gas balance
• Identification of key levers for optimizing environmental impacts
• Derivation of a process model to ensure transferability to other 3D printing processes

This project lays the foundation for modeling powder-bed-based 3D printing processes for polymers and enables a holistic assessment of greenhouse gas emissions. The findings serve as a modeling basis and guideline for other 3D printing processes and materials.