As a key part of global manufacturing, the foundry industry is under increasing pressure to improve its sustainability, as it faces traditionally high energy consumption and significant material waste. With the enhancement of environmental awareness, the industry must explore innovative solutions in line with sustainable practices. Additive manufacturing (AM), which used to be mainly utilised for prototyping, is emerging as a revolutionary technology with the potential to address these challenges, writes Yanyi Wu of China.
According to Precedence Research, the global additive manufacturing market was valued at $17.99 billion in 2023 and is expected to grow at an annual rate of 19.85 per cent in the next decade. Although it only accounts for two per cent of global manufacturing at present, it is predicted that AM will comprise over nine per cent by 2032, driven by its adoption across diverse sectors. AM is considered a key driver in promoting the sustainable development of the foundry industry, due to its ability to minimise waste, optimise resource use, and enable localised production. So, how does AM drive this transformation? What challenges must be overcome to achieve its full potential?
ADDITIVE MANUFACTURING AS A DRIVER OF SUSTAINABILITY
AM has emerged as a transformative force in the foundry industry, offering great potential for enhancing sustainability that is unparalleled by traditional methods. One of the primary advantages is the significant reduction in material waste. Conventional manufacturing processes, such as casting and machining, often involve subtracting material from a larger block, resulting in more than half of the original materials being discarded. In contrast, AM constructs components layer by layer, utilising only the necessary material to create the final part, thereby reducing material waste to near zero levels, particularly in aerospace and other industries requiring intricate geometries and high performance materials.
Energy efficiency is another important potential field for AM. Although some AM processes themselves may consume high energy, those involving metal production are, on the whole, more energy saving than traditional methods. For example, titanium components produced via AM can significantly reduce energy use by minimising the need for extensive machining, which usually generates up to eighty to ninety per cent scrap in traditional manufacturing. Innovations such as more efficient lasers and optimised printing strategies are being developed, which further improve the energy efficiency of these systems and make them more viable for use in the foundry industry.
Moreover, AM has a significant impact on the sustainability of the supply chain through localised production. Traditional manufacturing often requires producing parts in one location and then shipping them to various demand points globally. This not only escalates the carbon footprint associated with transportation but also amplifies the intricacy and expenses of manufacturing. In contrast, AM enables on demand production closer to the point of use, diminishing the necessity for long distance shipping and contributing to an overall reduction in environmental impact. For industries that necessitate swift prototyping or the production of highly customised parts, AM’s flexibility can shorten delivery times and reduce environmental costs.
OVERCOMING CHALLENGES IN IMPLEMENTING ADDITIVE MANUFACTURING
Technologically, AM has unlimited potential, but it struggles with limitations that affect its practicality for widespread use in the foundry sector. One of the most significant issues is the limited range of materials that can be effectively processed. Although AM is suitable for certain metals and alloys, the choice of available materials is still constrained in high performance applications. This is particularly problematic in the field of metal casting where the ability to handle many different materials is crucial. The production speed of AM also remains a bottleneck. Traditional manufacturing processes, such as casting, can produce parts in large quantities quickly. However, AM tends to be slow when dealing with complex geometries and large components. The disparity in production efficiency makes it difficult for AM to compete with conventional methods in terms of volume and speed.
Economic barriers should not be underestimated. Adopting AM technology requires huge initial investment, including the cost of acquiring advanced machinery and the continuous costs of maintenance and procurement of specialised materials (such as metal powders). These substantial costs present a significant challenge for small foundries, constraining their ability to integrate AM on a scale that would optimise their operations. Although AM can result in cost savings by reducing material waste and potentially decreasing energy consumption, these benefits typically take time to manifest, introducing financial risks that many companies are reluctant to assume.
The challenges of regulation and standardisation further complicate the picture. As AM is relatively new to the industrial landscape, many existing manufacturing standards do not fully account for the nuances of these processes. Regulatory gaps may lead to inconsistencies in product quality and difficulties in ensuring compliance with industry norms. The parts produced by AM lack standardised procedures and quality benchmarks, which adds to the difficulty of achieving reliable and repeatable results across different machines and materials. This variability poses a significant challenge for scaling up AM in the foundry industry, where precision and consistency are paramount.
Energy consumption is another critical issue, especially in the processes of metal based AM. Techniques such as laser sintering or electron beam melting are energy intensive and sometimes even negate the environmental benefits obtained by reducing material waste. The production of metal powders, a key input for many AM processes, is itself energy demanding. Many factors in energy consumption complicate the narrative that AM is essentially more sustainable, highlighting the importance of further improving energy efficiency within the technology.
FUTURE OUTLOOK: A SUSTAINABLE PATH FORWARD
As the foundry industry continues to evolve, the role of AM in driving sustainability is expected to expand significantly. AM has become a key technology in the transition towards more sustainable manufacturing practices by reducing material waste, enhancing energy efficiency, and localising production positions. Looking ahead, one of the most promising developments is to combine AM with the circular economy. By enabling on demand production and facilitating the recycling and reuse of materials, AM can significantly reduce the environmental footprint of manufacturing processes.
The progress of AM technology shows us the possibilities of broader adoption of more sustainable materials, such as recycled metals and bio based polymers, which will further amplify its environmental benefits. The future of AM also points towards greater manufacturing decentralisation, meaning production can occur closer to the point of use, which will not only reduce transportation emissions but also support local economies. However, to achieve this sustainable future, continuous technological innovation, industry wide collaboration, and supportive regulatory frameworks are needed to ensure that AM’s growth is consistent with environmental protection goals.
AUTHOR
Yanyi Wu is a research associate at the School of Public Affairs and the Institute of China’s Science, Technology and Policy at Zhejiang University, China.
Contact: [email protected]
Main Image: Shutterstock