While traditional manufacturing processes tend to consume more energy, generate substantial waste, and rely on extensive supply chains, 3D printing offers a streamlined and environmentally-conscious alternative.
Let’s explore the environmental benefits of 3D printing and see how it’s shaping a more sustainable future across many different industries.
The Environmental Benefits of 3D Printing on The Manufacturing Processes
1. Reduction in Material Waste
Traditional subtractive manufacturing processes often involve cutting or milling material from a larger block, resulting in significant raw material waste. The additive manufacturing process, on the other hand, builds products and parts layer by layer, depositing material only where it’s needed.
This process results in significantly less waste material which is great. However, many of the materials that we use at Prototal are reusable too. Our powdered materials are collected and reused to print other products. We also recycle any materials we can. For example, the powder we can’t use in our facilities is turned into filler for road paint.
Studies have shown that 3D printing can reduce material waste by up to 90% compared to traditional methods and the materials can be recycled in many different ways. So, 3D printing is a far more sustainable manufacturing process than traditional manufacturing. With sustainable and recycled materials in testing phases around the world, the sustainability benefits of additive manufacturing are set to continue to grow.
2. Energy Efficiency
The energy consumption of 3D printing varies depending on the technology and materials used. However, when comparing the entire lifecycle of a product, 3D printing often results in lower overall energy use when compared to a part made with traditional methods.
Traditional manufacturing typically requires energy-intensive processes, including material extraction and machining. Not to mention the carbon emissions, environmental impact and energy consumption used to transport the raw materials and parts created.
3. Localised Manufacturing and Shorter Supply Chains
With 3D printing, products and parts can be manufactured closer to their end-use location, reducing the need for long-distance shipping and the associated fuel consumption and emissions. Distributed, on-demand production eliminates the need for large warehouses and storage facilities, further cutting energy consumption.
Prototal, for example, has a network of 3D printing facilities across various locations in Europe. This means we can print parts in locations close to customers, minimising shipping distance and time and ensuring minimum downtime.
4. Material Innovation and Recycling
Many industries are now exploring the use of recycled plastics and bio-based materials for 3D printing applications. For instance, some companies have begun repurposing waste products such as plastic bottles and fishing nets into filaments for 3D printing, creating a circular economy where waste is minimised.
Prototal are at the forefront of this material innovation. Prototal Sweden is one of the founders of the Polymer Technology Institute, a Swedish business collaboration that finds new alternatives to polymer materials.
Biodegradable and Recyclable Materials.
3D printing technology also enables the use of biodegradable materials, such as PLA (polylactic acid), which is derived from renewable resources like cornstarch and sugarcane. Prototal Denmark is currently testing a new material based on castor beans which they hope to bring to market in the next few years.
As research progresses, the potential for using sustainable and recyclable materials will only increase, further enhancing the environmental benefits of the technology.
5. Lightweighting and Design Optimisation
One of the key advantages of 3D printing is its ability to produce complex geometries that would be impossible or cost-prohibitive with traditional manufacturing methods. This allows engineers to design parts that are lighter, yet stronger, leading to more efficient products with a lower environmental impact.
In the automotive and aerospace industries, for example, reducing the weight of components is a crucial strategy for reducing fuel consumption and emissions. 3D printing allows engineers to design parts with internal lattices and optimised structures, reducing weight without compromising strength.
This directly leads to reduced fuel usage and lower CO2 emissions during a vehicle’s operational life.
6. Reduction in Manufacturing Processes
Traditionally before a part can be made, additional tooling and jigs are needed before any work begins. Once a prototype is built, any amendments require iterations to the tooling and jigs.
3D printing simplifies the mass production process by reducing waste materials on jigs and tooling and unnecessary energy usage on machines producing these jigs and tooling. The saving of waste continues when the parts are made too. As 3D printing is additive, it only ever uses the material needed to build the part, and in some cases, to create support structures (which we recycle).
Reducing the manufacturing processes involved in creating a part not only has environmental implications, though. Mass production costs can be greatly reduced by additive manufacturing processes as well.
Key Takeaways
The environmental benefits of 3D printing are clear:
- Reduced material waste
- Energy savings
- More sustainable supply chains
- Opportunities for the use of recycled material.
Prototal is continuously working on improving our processes and increasing our usage of renewable energy at all of our sites to further the environmental benefits of 3D printing.
While there are still challenges to overcome, such as the energy intensity of certain 3D printing machines and the need for more widespread adoption of recycled materials, the potential for additive manufacturing to contribute to a more sustainable future is undeniable. As industries continue to explore and expand the applications of 3D printing, it will play an increasingly important role in reducing the environmental footprint of manufacturing.
For engineers and professionals in the field, understanding the environmental benefits of 3D printing is essential for harnessing its full potential and making informed decisions that align with the global shift towards sustainability.
Produce Sustainable Products and Parts With Prototal
Take the leap to a greener future with 3D printing and Prototal. Find out more about the materials we use, the sectors we work with and how our 3D printing services can revolutionise your industry today by getting in touch with our expert engineers.