A life cycle assessment-based approach for evaluating the influence of total build height and batch size on the environmental performance of electron beam melting

Electron beam melting (EBM) is emerged as a promising metal-based additive manufacturing technology. The technique allows the build of complex and fully dense metallic parts by using an electron beam to melt metallic powder layer by layer. This technique has been applied efficiently in aeronautic and automobile sectors, as well as biomedical engineering. However, the environmental performance of EBM is still an open question. This paper aims to offer a more comprehensive understanding on environmental impacts related to EBM process. A methodology based on life cycle assessment (LCA) method is proposed to evaluate environmental impacts related to EBM. In particular, the influence of different parameters, such as total build height, batch size (i.e., number of parts per build), and material waste due to support structures on the environmental performance of EBM is discussed. By comparing environmental impacts between (EBM + finishing machining) and conventional approach (i.e., machining) approaches, which are used to manufacture a same mechanical part, the environmentally friendly area of each manufacturing approach is also determined. The results show that the (EBM + finishing machining) approach becomes the best option on the environmental point of view when the total build height decreases and the batch size is close to a full build configuration. On the other hand, the amount of material waste due to support structures in EBM does not significantly influence on the environmental performance of the EBM process.