Comparative Life Cycle Assessment of molding process and 3D printing of High-Performance Long-fiber Reinforced Composites

Composite materials are widely employed to produce high-performance components. However, their usage is associated with significant environmental impacts, deriving from the constituent materials (e.g., carbon fiber and epoxy resin) and the manufacturing process. Traditional methods of composite manufacturing such as bag molding or compression molding were subjected to discussion due to their high energy requirements, related to the required heat and pressure, the use of molds and the production of composite scraps. In contrast, 3D printing presents a promising alternative, that could reduce material waste and energy consumption. This study investigates an innovative 3D printing process for high-performance composites, in particular continuous carbon fiber and thermosetting epoxy matrix, with the aim of investigating its environmental impact. A comprehensive Life Cycle Assessment (LCA) was conducted to compare the environmental footprints of traditional molding and 3D printing processes of continuous fiber composites. A wide range of factors such as energy consumption, resource utilization, greenhouse gas emissions, and waste generation was considered. The outcomes of this comparative LCA reveal a significant reduction in environmental impacts associated with the innovative 3D printing system with respect to traditional methods. These findings offer crucial insights into the sustainability of 3D printing for high-performance composites, providing a valuable decision-making tool for industries seeking eco-friendly manufacturing solutions..