Enabling Product Carbon Footprint Management in the Material Extrusion Process

Abstract

The environmental impact of new products and production processes is one of the most important indicators of the current time. Many methods exist to estimate ecological metrics, such as the Product Carbon Footprint (PCF) in the individual product development phases with stand-alone software. However, methods to integrate the PCF in the entire process chain with the possibility to interact in the process are missing. This paper presents a new approach to measuring the ecological impact of an Additive Manufacturing production process, exemplified by the Material Extrusion (MEX) process. The novelty of the approach lies in implementing a single software for machine control, processing, and visualization of sensor signals, parameter variation, and reporting functions to enable comprehensive PCF management. The workflow includes a model-based prediction of the PCF based on the G-code, live monitoring during the production phase, and a subsequent automated evaluation at a central interface. Critical points can be identified, and approaches for optimizing the MEX process can be designed. Uncertainty evaluation of the PCF based on the combination of uncertainty of the sensors and the Life Cycle Assessment is included in the method. The developed prototype software can be used in the design phase for prediction and in the process phase for optimization, enabling seamless PCF management for the MEX process.