Sustainable Manufacturing Research Articles (Page 1)

Abstract Thermoplastic materials such as Polylactic acid (PLA), Acrylonitrile butadiene styrene (ABS) and Nylon 6 have made extensive use of fused filament manufacturing (FFM) process, but little is known about how material-specific process parameters affect mechanical processes according to manufacturing cost and product performance. This present investigation fills these gaps by deciphering the understudied links between the surface improvisation and characteristic property enhancement through FFM process. In this research, the aforementioned thermoplastic materials are manufactured in the form of test specimens as per the American society for testing and material(ASTM) standard and undergone with silinization process for enhancing the matrix stress transfer and interlayer stability. Few interesting improvements like less porosity in PLA, interlayer adhesion in ABS and grouped polymer structures in the Nylon 6 were noticed in structural evaluation, these findings exhibit pivotal role in improving the flexural stiffness (~54.22 MPa) and toughness (4.83 J) owing to strong interlayer bonding and semi-crystalline phases. ABS exhibited anisotropic interfaces during bonding and interaction of internal-thermal stresses, these phenomena created potential weak points and resulted with slight reduction of flextural strength (~1.08 MPa) and tensile strength ~5.22 MPa than PLA specimens. Compared with PLA and ABS, superior bonding and molecular orientation has exhibited highest tensile strength (~48.5 MPa) in the Nylon 6 specimen. Moreover, Nylon 6 has provided glass transition 60°C and a broad melting peak ~ 220°C with better thermal stability. Anisotropy and molecular interactions determine fluctuating Shore D hardness values also the formation of unique fracture patterns exhibits distinct features for all three test specimens. Obtained results in the context reveals the improvements in quality and process stability of the FFM process and its utilization in producing the components with reasonable cost.

Abstract A sustainable manufacturing route in the form of resource-efficient bottom pouring stir casting process which minimizes material wastage, was used to create Nano Metal Matrix Composites (NMMCs) of aluminum alloy LM13 reinforced with nano-sized zirconium oxide (ZrO₂) particles. At different weight percentages (2.5–12.5 wt.%), nano-ZrO₂ particles with an average size of 80 nm were added to the LM13 matrix. While EDS shows the existence of ZrO₂ in the composite, optical microscopy and SEM microstructural investigations verified homogeneous particle dispersion, good interfacial bonding, and low porosity. Although experimental values show somewhat lower because to casting porosity, both theoretical and experimental densities increases with reinforcement content. The hardness, ultimate tensile strength, and yield strength gradually increase as the ZrO₂ content rises from 2.5 to 10 wt.%; however, a minor decline is noted at 12.5 wt.% as a result of particle aggregation and microstructural flaws. As ZrO₂ addition increases, the percentage elongation continuously declines, suggesting decreased ductility. The addition of ZrO₂ greatly improved mechanical characteristics, with ultimate tensile strength peaking at 240.5 MPa at 10 wt.% reinforcement and micro-vickers hardness reaching 133.3 HV (~39% improvement) due to dispersion strengthening and grain refinement. Additionally, yield strength increased by about 34% (138.6 MPa). However, at 12.5 wt.% ZrO₂, minor strength decreases were noted, which were ascribed to microstructural flaws and particle agglomeration. As reinforcement increased, fractography showed a shift from ductile to brittle fracture, which was correlated with decreased ductility. Overall, the study shows that the strength and wear resistance of the composite can be efficiently tailored by optimizing the nano-ZrO₂ content in LM13 alloy, creating a lightweight composite design which offers potential for reducing carbon emissions in automotive, aerospace and allied industrial applications.

With the continuous growth of industrial activities and increasing awareness of environmental protection, research and development of lubricants have at-tracted significant attention. Water-soluble lubricating additives, as environ-mentally friendly lubricants, play a crucial role in reducing environmental pol-lution and improving production efficiency. This paper reviews recent advances in novel water-soluble lubricating additives, focusing on their classification, performance advantages, and applications across various industries. These addi-tives not only enhance lubrication and wear resistance but also contribute to sustainable manufacturing by lowering energy consumption and minimizing harmful emissions. Furthermore, the review discusses the challenges and future prospects of water-soluble lubricating additives, highlighting their potential to drive innovation in green lubrication technologies. The integration of new ma-terials and tribological understanding promises to expand their practical utility, making them indispensable in modern industrial lubrication systems.

Among nickel-based superalloys, Inconel® 725 (IN725) stands out for its excellent strength and corrosion resistance. Despite this, its application in additive manufacturing remains largely unexplored. This study investigates laser powder bed fusion of metals (PBF-LB/M) applied to IN725 powder derived from recycled industrial waste, addressing sustainability and process optimization goals. Using the design of experiments approach, the laser power–scan speed process parameter space was explored. Gaussian process regression models were developed to predict surface roughness, relative density, and microhardness. Both direct process parameters and volumetric energy density were evaluated as model inputs to assess predictive performance. The findings established a broad optimal process window for manufacturing high-quality IN725 parts using PBF-LB/M. Specifically, an optimal combination of 99.99% relative density, 7.3 μm roughness, and 311 HV microhardness was achieved by processing the powder at 250 W and 1,500 mm/s. By demonstrating the feasibility of using recycled IN725 powder, this study contributes to the development of sustainable manufacturing practices and supports wider adoption of PBF-LB/M in oil and gas, marine, and chemical processing industries, where IN725 is widely employed.

When the public is asked to name the most globally sustainable industries, they typically respond with solar, wind, geothermal, or EVs. Yet, who would ever imagine the pulp & paper industry, which is often caricatured as a relic, is in fact one of the largest and most secretly sustainable manufacturing sectors. Its entire infrastructure and operations are built on replenishable forests and powered by renewable energy streams to produce recyclable, biodegradable products. The pulp & paper industry has a story that deserves retelling in the age of sustainability metrics and ESG frameworks. Our editorial embarks on a short simple journey to reframe pulp & paper not as a legacy industry, but as a model for sustainable manufacturing by using a clear, quantifiable system to demonstrate its global environmental impact.

This research addresses the growing global challenge of plastic waste, resource depletion, and industrial reliance on non-renewable materials by exploring the potential of eggshell powder (ESP) as a biodegradable and renewable alternative in sustainable product design. Although significant progress has been made in biopolymer and composite development, much of the research remains fragmented, with limited integration of material science findings into industrial design frameworks. The aim of this study is to conceptualize the role of ESP in advancing biodegradable materials and renewable materials innovation within the context of sustainable product design. Adopting a mixed-method conceptual approach, the study synthesizes recent empirical findings, analyzes laboratory-based performance data, and reviews relevant theoretical frameworks including eco-design and circular economy models. Findings indicate that ESP can enhance barrier and thermal properties in bioplastics, improve compressive strength in cementitious systems at low substitution levels, and serve as a precursor for higher-value applications such as hydroxyapatite production. However, performance trade-offs remain, particularly in tensile strength and workability, and challenges persist in scaling, dispersion, and user-centered adoption. The study implies that ESP has strong potential for integration into sustainable manufacturing and design practices, particularly in Malaysia where eggshell waste is abundant. It concludes that bridging technical optimization with circular economy strategies and design-for-sustainability principles will be critical to transforming ESP from laboratory experimentation into viable industrial practice.

This paper examines how green procurement and government policy affect the performance of Fast-Moving Consumer Goods (FMCG) companies in Nigeria. While sustainability is gaining global relevance, limited empirical evidence addresses how these drivers influence firm outcomes in Nigeria. The study investigates the extent to which green procurement and government policy shape organisational performance in the FMCG sector. A cross-sectional survey was conducted with 357 supply chain personnel across some listed FMCG firms. Data were analysed using ordinary least squares regression to establish the impacts of the variables. The regression results show that sustainable manufacturing (β = 0.192, p < 0.001) had the strongest positive effect on performance, followed by reverse logistics (β = 0.164, p < 0.001), Government policy (β = 0.133, p = 0.001), and green packaging (β = 0.117, p = 0.001). The model explained 41.2% of performance variation. Firms need to embed green procurement by strengthening supplier evaluation, investing in capacity-building, and ensuring transparent sourcing. Policymakers should enforce regulations consistently and introduce fiscal incentives to promote sustainability, while stakeholders collaborate to align practices with long-term sectoral performance goals.

As the dominant methane elimination mechanism on Earth, the anaerobic oxidation of methane (AOM) presents significant potential for methane-to-chemical conversion biotechnology owing to its exceptional carbon and energy utilization efficiency. However, technological advancement faces critical challenges: the inherent unculturability of native AOM-performing methanotrophic archaea under pure growth conditions and their genetic intractability. To overcome these limitations, this study employed Methanosarcina acetivorans, a genetically tractable methanogenic archaeon capable of reversed methanogenesis-mediated AOM, as an engineered chassis for polyhydroxybutyrate (PHB) bioproduction from methane. Through heterologous pathway engineering, we established a synthetic methanotrophic platform integrating an exogenous PHB biosynthesis module. Furthermore, we developed an innovative extracellular electron transfer system utilizing straw-derived biochar as an electron acceptor. Characterization revealed that Fenton-modified biochar demonstrated superior AOM-enhancing performance, which can be attributed to its enhanced electron-accepting capacity. The optimized system combining engineered M. acetivorans with Fenton-biochar achieved ∼0.20 g/L of PHB titer under methane-fed conditions. Isotopic tracing using 13C-labeled methane conclusively demonstrated the incorporation of methane-derived carbon into PHB molecules. The circular economy approach demonstrated here establishes a novel paradigm for greenhouse gas conversion and sustainable chemical manufacturing, with potential applications extending to other value-added bioproducts synthesis from methane.

The rapid growth of 3D printing in university makerspaces has created a new but often overlooked waste stream: discarded polylactic acid (PLA) filament from failed prints, support structures, and design errors. Although PLA is a bio-based and recyclable thermoplastic, most of this material currently ends up in landfills. This paper outlines a pilot project at NC State University to close this loop by collecting, processing, and re-extruding PLA waste into new 3D printing filaments. The system, developed through collaboration between the D.H. Hill Makerspace and Hodges Lab, employs a straightforward four-step process—collection, sorting, grinding, and extrusion—thereby achieving over 90% material efficiency. Besides demonstrating technical feasibility, the project emphasizes how campus-scale circular systems can reduce waste, lower costs, and serve as educational models for sustainable manufacturing. This initiative provides a replicable framework for universities and small-scale fabrication facilities seeking to incorporate circular economy principles into their operations.

Life Cycle Carbon Footprint Modular Analysis of Leather Products for Sustainable Manufacturing

The fashion and textile industry (FTI) is a significant contributor to greenhouse gas emissions, resource consumption, and waste generation, necessitating sustainable alternatives. Chitosan, a biodegradable and renewable biopolymer, has shown potential in reducing environmental impact throughout the textile lifecycle. However, existing studies often focus on isolated applications rather than its broader role in industrial sustainability. This review synthesises findings from 142 academic studies to assess chitosan’s applications in textile production, dyeing, finishing, and waste management, emphasising its impact on energy efficiency, carbon reduction, and resource circularity. Chitosan’s biodegradability, antimicrobial properties, and affinity for sustainable dyeing offer a viable alternative to synthetic materials while also enhancing wastewater treatment and eco-friendly finishing techniques. By evaluating its contributions to sustainable manufacturing, this review highlights its potential in supporting decarbonisation and circular economy transitions within the textile sector, while also identifying challenges for future research.

Mechanochemical synthesis of hydrochlorothiazide-nicotinamide cocrystal: from batch-based ball-milling to scale-up ready hot melt extrusion.

Hierarchical diffusion-assembly-crosslinking strategy for sustainable leather manufacturing by polyphenol derivatives and Al(Ⅲ)

Sustainable additive manufacturing: Microstructural evolution and mechanical viability of recycled Flax/PP via fused granular fabrication

Microplastic emissions in textile wet processing: Progress, challenges, and mitigation strategies.

Enhancing the productivity of caproic acid in open culture chain elongation: A comparative study of biofilm systems.

Traditional clay brick manufacturing relies on wood and fossil fuels, leading to high energy consumption, harmful emissions, and increased costs. This study proposes a sustainable solution using a metallic kiln with double-layer insulation and a parabolic dish solar concentrator to improve energy efficiency and reduce environmental impact. Heated air from the solar concentrator receiver is directed through clay bricks in a fiberglass-insulated metallic kiln, enhancing heat retention and temperature control. A fan regulates heat and humidity, while hot air recirculation minimizes energy wastage. Moreover, moisture removal is managed by adjusting air vents. The clay bricks (0.225m × 0.11m × 0.075m) were tested for compressive strength, modulus of rupture, and water absorption on the 7th, 28th, and 56th days of drying. The compressive strength improved from 2.63 N/mm² on day 7 to 7.20 N/mm² on day 56. The findings highlight the potential of this system to improve brick quality, enhance energy efficiency, and reduce environmental impact.

This study investigates the influence of the Minimum Quantity Lubrication (MQL) technique and spindle speed on the surface roughness of AISI 1020 steel during turning operations. recycled cooking oil was utilized as an environmentally friendly MQL lubricant, offering potential as a substitute for conventional mineral oils. In this experiment, two independent variables were considered: the lubrication condition (MQL and dry cutting) and spindle speed, which was tested at three levels (630 rpm, 800 rpm, and 1000 rpm). The dependent variable was surface roughness. MQL was selected due to its ability to enhance cooling and lubrication efficiency while minimizing environmental impacts. Experimental results indicated that at a spindle speed of 1000 rpm, surface roughness achieved 2,221 µm with MQL, compared to 2,824 µm without MQL. These findings highlight that recycled cooking oil-based MQL significantly improves the surface finish and demonstrate that the proper combination of lubrication parameters and spindle speed enhances machining quality. Moreover, this research supports sustainable manufacturing by promoting the use of Recycled Cooking Oil as a green lubricant alternative.

Biodegradable polymers and biocomposites in sustainable additive manufacturing: A review.

In the research stream of sustainable reconfigurable manufacturing systems, sustainable and resilient supplier scrutiny and selection emerges as a key strategy, emphasising the imperative of integrating sustainability and resiliency into the supply chain fabric. This paradigm extends beyond mere economic evaluations by incorporating environmental stewardship, social responsibility, and resilience against disruptions into the supplier assessment processes. While studies in these fields have made significant strides, there remains a scarcity of research investigating and providing performance appraisal approaches for sustainable-resilient suppliers within such systems. Motivated by addressing the recognised gap, this study aims to identify key criteria for scrutinising sustainable-resilient suppliers through a state-of-the-art review and develop an intelligent data-driven model that incorporates fuzzy logic to effectively navigate uncertainties, leveraging AI-based capabilities to enhance supplier scrutiny and selection in complex systems. To this end, the paper presents an illustrative case to demonstrate the practical configuration of the proposed approach as well as a case study to corroborate its validity. The case studies confirmed that the model effectively assesses sustainable-resilient suppliers, improving precision and execution time while providing insights for informed decision-making through its analytical depth and computational efficiency. Furthermore, sensitivity analysis and its integration into the model are discussed.