The Additive Manufacturers Green Trade Association (AMGTA) is the first organization dedicated to the sustainability of 3D printing, aiming to conduct practical research on the use of energy and materials in 3D printing. In April 2023, the polar bears learned, AMGTA released its first independent study.
The report, commissioned by AMGTA and written by Rochester Institute of Technology's Golisano Institute for Sustainability, entitled "Comparing Life Cycle Assessment of Low-Pressure Turbine (LPT) Supports Through Two Manufacturing Methods," was a two-year study. The impact of producing parts using laser powder bed fusion of metals versus CNC machining was compared, and the impact of a 50% weight reduction on aircraft life. Ultimately, the study couldn't determine which manufacturing method used more energy, but it did confirm that lightweighting commercial aircraft engines and airframes has a significant impact on carbon emissions.
Sherri Monroe, Executive Director of AMGTA said: "The release of this peer-reviewed LCA is unprecedented, a milestone for AMGTA and the first time we have been able to publish tangible results. The importance of design needs to be considered even more. This research shows the real impact of additive manufacturing on future aircraft and engine design, and lays the research foundation for the use of additive manufacturing technology in other industries and projects."
The bracket under study is one of 12 brackets that connect the fuel manifold to the low-pressure turbine module casing of two GE Aviation CF6-80C2B6F turbine engines on a Boeing 767. The part, chosen for its simplicity, was redesigned and produced by AMGTA member Sintavia on an EOS M290 3D printer using Höganäs AB Inconel 718 powder. Meanwhile, traditionally manufactured parts are CNC machined by a Tennessee-based machine shop.
According to Sintavia, the optimized AM bracket weighs 50 percent less than the original version, or 0.063 kilograms, while featuring enhanced mechanical properties, including a longer fatigue life. The study estimates that for every kilogram of body weight lost, carbon emissions are reduced by 13,376 kilograms.
Brian Neff, CEO of Sintavia and Chairman of the AMGTA, said: "This study highlights the importance of using AM to develop optimized parts and assemblies that have been lightweighted using AM technology. There is currently no other commercially viable technology as Having such an immediate impact on carbon emissions through AM lightweighting aircraft components, we have now independently verified, peer-reviewed data to prove it. Looking forward to working with Boeing, GE and all OEMs in the industry to continue to unleash the power of AM sustainable potential."
The AMGTA noted that compared with previous similar studies, the study showed that AM uses additional advantages over traditional methods. Two of the three LCA methods showed that traditional scaffolds required less energy to produce, while one showed that 3D printed scaffolds produced fewer emissions. The LCA was performed in accordance with ISO 14040:2006(E) and was peer reviewed by EarthShift Global. Previous studies, as well as this study, have argued that energy trumps other factors in determining the greenhouse gas emissions of manufacturing technologies themselves. This is because the nature of energy determines how much energy use contributes to global warming. For example, a facility running entirely on solar power will be more sustainable than one plugged into a fossil fuel energy grid, but running on renewable energy is not a long-term solution for resource use.
Sherri Monroe added: "This study consists of two phases, production and use, where additive manufacturing has a low environmental impact, provides a more resilient, efficient and sustainable supply chain, and has a significant impact on the manufacturing ecosystem, to provide more sustainable solutions. Although this research is specific to the aircraft engine and aircraft body, the results of the in-service phase can be extended to any part of the aircraft that may be lightweighted, including mechanical systems, seats, service push Cars, etc., can even be extended to vehicles, ships, and trains.
