Session: 03-13-01: Manufacturing: General I

Paper Number: 172781

Additive Manufacturing With Lens of Environmental Sustainability 

Additive Manufacturing (AM), commonly referred to as 3D printing, is an emerging and transformative technology that holds significant promise for industrial-scale production. Unlike conventional manufacturing, which often involves subtractive processes or the need for molds and dies, AM builds components layer by layer, directly from digital models. This unique approach enables greater design flexibility, reduced lead times, and the potential for on-demand, localized production. As the global environmental crisis intensifies, it becomes increasingly important to assess the ecological implications of new manufacturing technologies like AM. While AM offers many operational and economic benefits, its environmental performance across the entire life cycle must be carefully examined to ensure it supports long-term sustainability goals. One of AM’s major advantages is the reduction or complete elimination of certain resource-intensive steps commonly found in traditional methods such as casting, machining, molding, and welding. This streamlining of the manufacturing process not only lowers production costs but also results in reduced material waste, energy use, and transportation emissions. This study presents a critical review and comparative life cycle assessment (LCA) of well-established metal AM technologies versus traditional casting methods. The environmental performance is evaluated by simulating the fabrication of a pump impeller, a component widely used in industrial applications, using both a representative metal AM process and a conventional casting process. The LCA methodology is applied across five distinct stages of the impeller’s life cycle, from raw material extraction to end-of-life disposal. The analysis reveals that AM has the potential to significantly reduce environmental impacts compared to casting. Specifically, AM shows a 15% reduction in Global Warming Potential (GWP), 20% in Acidification Potential (AP), 65% in Freshwater Aquatic Ecotoxicity Potential (FAETP), 20% in Human Toxicity Potential (HTP), and 10% in Stratospheric Ozone Depletion Potential (ODP). These findings highlight the environmental benefits of AM, particularly in applications where lightweight, complex, or custom parts are needed. Moreover, the environmental footprint of AM can be further improved through the integration of renewable energy sources, especially during the pre-manufacturing and manufacturing stages, which are typically the most energy-intensive. The use of hydroelectric or solar electricity can serve as a transitional strategy to reduce emissions until advancements in AM technology lead to lower energy consumption per part produced. In conclusion, while AM is not without its environmental challenges, it offers a promising path toward more sustainable manufacturing. This study recommends further research into optimizing process parameters, improving material efficiency, and scaling the use of renewable energy in AM systems to enhance their sustainability across industrial sectors.

 

Presenting Author: Behnaz Rezaie University of Pittsburgh

Presenting Author Biography: Dr. Behnaz Rezaie is a globally recognized expert in sustainable energy systems, with a distinguished career spanning academia, industry, and applied research. With over a decade of experience in engineering education and more than 10 years in the automotive and manufacturing sectors, she bridges the gap between cutting-edge research and practical application.
Her research focuses on improving the efficiency, sustainability, and resilience of district energy systems, with deep expertise in thermal energy storage, renewable integration, and the energy-water nexus. Dr. Rezaie has developed innovative models to optimize multiple thermal energy storages, evaluated alternative energy technologies under economic and environmental constraints, and pioneered methods for sustainable energy planning in smart cities. Her contributions include advanced simulations for server room cooling using AI, lifecycle assessments of additive manufacturing, and guidelines for geothermal energy systems. Dr. Rezaie is the author of over 50 peer-reviewed journal and conference publications, including a landmark review on district energy systems recognized as a “Highly Cited Paper” by Applied Energy (Impact Factor 11.44). She has secured over $1.5 million in research funding as PI or Co-PI from agencies such as DOE, DOD, and industrial partners, and has led multi-disciplinary projects in energy optimization, sustainability assessment, and water conservation.
In industry, Dr. Rezaie has held senior engineering and managerial roles, including the launch of over 140 automotive programs and the development and accreditation of six quality assurance laboratories for automakers such as Toyota, Chrysler, Mazda, and KIA. She is a registered Professional Engineer (P.Eng) in Ontario, Canada.
Currently serving as an Assistant Professor at the University of Pittsburgh, Dr. Rezaie continues to advance the field through teaching, mentorship, and leadership. She has delivered keynote speeches at international conferences, served as Associate Editor for multiple engineering journals, and chaired global events like the World Energy Storage Conference.
Dr. Rezaie’s career is defined by her commitment to environmental stewardship, technological innovation, and empowering the next generation of engineers through education and outreach.

Authors:

Behnaz Rezaie University of Pittsburgh
Fardad Azarmi North Dakota State University
Ladan Momayez University of Pittsburgh