Environmental Dimensions of Additive Manufacturing: Mapping Application Domains and Their Environmental Implications
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Summary: Additive manufacturing (AM) proposes a novel paradigm for engineering design and manufacturing, which has profound economic, environmental, and security implications. The design freedom offered by this category of manufacturing processes and its ability to locally print almost each designable object will have important repercussions across society. While AM applications are progressing from rapid prototyping to the production of end‐use products, the environmental dimensions and related impacts of these evolving manufacturing processes have yet to be extensively examined. Only limited quantitative data are available on how AM manufactured products compare to conventionally manufactured ones in terms of energy and material consumption, transportation costs, pollution and waste, health and safety issues, as well as other environmental impacts over their full lifetime. Reported research indicates that the specific energy of current AM systems is 1 to 2 orders of magnitude higher compared to that of conventional manufacturing processes. However, only part of the AM process taxonomy is yet documented in terms of its environmental performance, and most life cycle inventory (LCI) efforts mainly focus on energy consumption. From an environmental perspective, AM manufactured parts can be beneficial for very small batches, or in cases where AM‐based redesigns offer substantial functional advantages during the product use phase (e.g., lightweight part designs and part remanufacturing). Important pending research questions include the LCI of AM feedstock production, supply‐chain consequences, and health and safety issues relating to AM.
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AM processes currently show high production costs, low throughput rates, surface roughness, and part fatigue life limitations, factors that limit their near-term application.
“AM processes currently show high production costs, low throughput rates, surface roughness, and part fatigue life limitations [157][158][159], factors that limit their near-term application.”
From Material efficiency strategies to reducing greenhouse gas emissions associated with buildings, vehicles, and electronics—a review (2019) · cites this paper as [158]
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Nascimento, D. L. D. M., Alencastro, V., Quelhas, O. L. G., Caiado, R. G. G., Garza‐Reyes, J. A., Rocha-Lona, L., & Tortorella, G. L. (2018) · Journal of Manufacturing Technology Management · doi:10.1108/jmtm-03-2018-0071 · Cited by 907 · see citing works
Plocher, J., & Panesar, A. S. (2019) · Materials & Design · doi:10.1016/j.matdes.2019.108164 · Cited by 676 · see citing works
Metal additive manufacturing in the commercial aviation industry: A review
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An overview of modern metal additive manufacturing technology
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Hertwich, E. G., Ali, S., Ciacci, L., Fishman, T., Heeren, N., Masanet, E., Asghari, F. N., Olivetti, E., Pauliuk, S., Tu, Q., et al. (2019) · Environmental Research Letters · doi:10.1088/1748-9326/ab0fe3 · Cited by 477 · see citing works
The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review
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Review of high-strength aluminium alloys for additive manufacturing by laser powder bed fusion
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Environmental assessment of additive manufacturing in the automotive industry
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Kellens, K., Mertens, R., Paraskevas, D., Dewulf, W., & Duflou, J. R. (2017) · Procedia CIRP · doi:10.1016/j.procir.2016.11.153 · Cited by 285 · see citing works
Self-citationLife cycle assessment of additive manufacturing processes: A review
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Exploring the influence of industry 4.0 technologies on the circular economy
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Exploring the potential of additive manufacturing for product design in a circular economy
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Kerdlap, P., Low, J. S. C., & Ramakrishna, S. (2019) · Resources Conservation and Recycling · doi:10.1016/j.resconrec.2019.104438 · Cited by 234 · see citing works
Sustainability through alloy design: Challenges and opportunities
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Use of Biomaterials for 3D Printing by Fused Deposition Modeling Technique: A Review
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Salifu, S. A., Desai, D. A., Ogunbiyi, O., & Mwale, K. (2022) · The International Journal of Advanced Manufacturing Technology · doi:10.1007/s00170-021-08569-z · Cited by 166 · see citing works
Note on the Rate and Energy Efficiency Limits for Additive Manufacturing
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Self-citationSaade, M. R. M., Yahia, A., & Amor, B. (2019) · Journal of Cleaner Production · doi:10.1016/j.jclepro.2019.118803 · Cited by 163 · see citing works
Jung, S., Kara, L. B., Nie, Z., Simpson, T. W., & Whitefoot, K. S. (2023) · Environmental Science & Technology · doi:10.1021/acs.est.2c04927 · Cited by 153 · see citing works
Additive manufacturing and supply chains–a systematic review
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Life cycle engineering of lightweight structures
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Review of High-Performance Sustainable Polymers in Additive Manufacturing
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Design and Tailoring of Alloys for Additive Manufacturing
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Corbett, C. J. (2018) · Production and Operations Management · doi:10.1111/poms.12837 · Cited by 128 · see citing works
Carve, M., & Włodkowic, D. (2018) · Micromachines · doi:10.3390/mi9020091 · Cited by 118 · see citing works
Yang, S. L., Min, W., Ghibaudo, J., & Zhao, Y. F. (2019) · Journal of Cleaner Production · doi:10.1016/j.jclepro.2019.05.380 · Cited by 108 · see citing works
Sustainability and environmental impact of fused deposition modelling (FDM) technologies
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A Review on Development of Bio-Inspired Implants Using 3D Printing
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3D printing towards implementing Industry 4.0: sustainability aspects, barriers and challenges
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Industry 5.0 and Triple Bottom Line Approach in Supply Chain Management: The State-of-the-Art
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The benefits of additive manufacturing for sustainable design and production
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Priarone, P. C., Catalano, A. R., & Settineri, L. (2023) · Progress in Additive Manufacturing · doi:10.1007/s40964-023-00395-x · Cited by 85 · see citing works
Cost- and energy-efficient manufacture of gears by laser beam melting
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Self-citationA vision for sustainable additive manufacturing
Graziosi, S., Faludi, J., Stanković, T., Borgianni, Y., Meisel, N. A., Hallstedt, S. I., & Rosen, D. W. (2024) · Nature Sustainability · doi:10.1038/s41893-024-01313-x · Cited by 83 · see citing works
Peng, S., Li, T., Zhao, J., Lv, S., Tan, G. Z., Dong, M., & Zhang, H. (2019) · Journal of Cleaner Production · doi:10.1016/j.jclepro.2019.04.187 · Cited by 81 · see citing works
A Deep Look at Metal Additive Manufacturing Recycling and Use Tools for Sustainability Performance
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Prakash, C., Singh, S., Kopperi, H., Ramakrihna, S., & Mohan, S. V. (2020) · Journal of Cleaner Production · doi:10.1016/j.jclepro.2020.125164 · Cited by 84 · see citing works
Peng, T., Wang, Y., Zhu, Y., Yang, Y., Yang, Y., & Tang, R. (2020) · Additive manufacturing · doi:10.1016/j.addma.2020.101530 · Cited by 80 · see citing works
Life cycle assessment of integrated additive–subtractive concrete 3D printing
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Ansari, M. A., Crampton, A., Garrard, R., Cai, B., & Attallah, M. M. (2022) · The International Journal of Advanced Manufacturing Technology · doi:10.1007/s00170-022-08995-7 · Cited by 79 · see citing works
Recent progress towards photovoltaics’ circular economy
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Sustainable Additive Manufacturing and Environmental Implications: Literature Review
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The benefits and barriers of additive manufacturing for circular economy: A framework proposal
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Priarone, P. C., Lunetto, V., Atzeni, E., & Salmi, A. (2018) · Procedia CIRP · doi:10.1016/j.procir.2018.09.058 · Cited by 75 · see citing works
Electrical energy and material efficiency analysis of machining, additive and hybrid manufacturing
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Self-citationSustainability of metal powder additive manufacturing
Fredriksson, C. (2019) · Procedia Manufacturing · doi:10.1016/j.promfg.2019.04.018 · Cited by 73 · see citing works
The sustainability of emerging technologies for use in pharmaceutical manufacturing
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“, increasing the use of AM within all industries would contribute to decreasing the annual CO2 impact by 328 metric tonnes [55] (Figure 3).”
BackgroundFranco, D., Ganga, G. M. D., de Santa-Eulália, L. A., & Filho, M. G. (2020) · Computers & Industrial Engineering · doi:10.1016/j.cie.2020.106713 · Cited by 69 · see citing works
3D food printing: nutrition opportunities and challenges
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Lunetto, V., Galati, M., Settineri, L., & Iuliano, L. (2020) · Additive manufacturing · doi:10.1016/j.addma.2020.101115 · Cited by 68 · see citing works
Sinclair, M. A., Sheldrick, L., Moreno, M., & Dewberry, E. (2018) · Sustainability · doi:10.3390/su10062088 · Cited by 66 · see citing works
Material Extrusion-Based Additive Manufacturing with Blends of Polypropylene and Hydrocarbon Resins
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Liu, Z., Jiang, Q., Ning, F., Kim, H., Cong, W., Xu, C., & Zhang, H. (2018) · Sustainability · doi:10.3390/su10103606 · Cited by 65 · see citing works
An analysis of the global additive manufacturing response to the COVID-19 pandemic
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Holmström, J., & Gutowski, T. G. (2017) · Journal of Industrial Ecology · doi:10.1111/jiec.12580 · Cited by 64 · see citing works
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Ramos, A., García-Angel, V., Siqueiros-Hernández, M., Sahagun, T., González-Uribe, L. A., & Ballesteros, R. (2025) · Materials · doi:10.3390/ma18061377 · Cited by 63 · see citing works
Charting the Environmental Dimensions of Additive Manufacturing and 3D Printing
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Self-citationA novel method to forecast energy consumption of selective laser melting processes
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COMPARING ENVIRONMENTAL IMPACTS OF METAL ADDITIVE MANUFACTURING TO CONVENTIONAL MANUFACTURING
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Selection for additive manufacturing using hybrid MCDM technique considering sustainable concepts
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Additive manufacturing potential for medical devices and technology
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- Authors
- Kellens, K., Baumers, M., Gutowski, T. G., Flanagan, W., Lifset, R., & Duflou, J. R.
- Affiliations
- KU Leuven (BE)
- University of Nottingham (GB)
- Massachusetts Institute of Technology (US)
- General Electric (United States) (US)
- Yale University (US)
- Corresponding author
- Kellens, Karel
- Venue
- Journal of Industrial Ecology
- Published
- 2017-08
- Volume
- 21
- Issue
- S1
- ISSN
- 1088-1980 (ISSN-L)
- 1530-9290
- OpenAlex
- W2741018071
- Cited by
- 310
- References
- 96
- Citations by year
- 2026: 32 · 2025: 42 · 2024: 37 · 2023: 50 · 2022: 34 · 2021: 25 · 2020: 37 · 2019: 29 · 2018: 17 · 2017: 7
- FWCI
- 15.61
- Type
- journal article
- Language
- en
- Open access
- hybrid
- doi.org
- Licence
- Locations
- Journal of Industrial Ecology (publishedVersion, cc-by)
- Lirias (submittedVersion, other-oa)
- DSpace@MIT (Massachusetts Institute of Technology) (submittedVersion, cc-by-nc)
- Repository@Nottingham (University of Nottingham) (submittedVersion, cc-by)
- Wiley eBooks
- Funders
- GOA SUMMA
- Topics
- Physical Sciences › Engineering › Automotive Engineering › Additive Manufacturing and 3D Printing Technologies
- Physical Sciences › Environmental Science › Environmental Engineering › Environmental Impact and Sustainability
- Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
- Keywords
- additive manufacturing, environmental impact, life cycle inventory, energy consumption, material consumption, waste and pollution, health and safety, feedstock production, supply chain, remanufacturing, lightweight design, conventional manufacturing comparison
About these checks
Registry, retraction, Cites and statistics results are computed, not judged, with one exception: a printed reference that no index lists is read once by a model before it counts as a citation error. Claims are extracted by a model and kept only when their quote appears verbatim in the text; each cited source is then checked, with a model’s help, for whether it says what the claim relies on. Those verdicts can be wrong — read the claim’s quote and the cited source before relying on one.
Statistics and arithmetic are recomputed, not judged.
Confidence bands are shown only for fields calibrated on our annotated test set. None is calibrated yet, so no band is shown.
What counts as a claim ›How we measure confidence ›How we check this ›
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