Green 3D Printing: From Berkeley to the World Jeremy Faludi, Susan - - PowerPoint PPT Presentation

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Green 3D Printing: From Berkeley to the World Jeremy Faludi, Susan - - PowerPoint PPT Presentation

Sep 08, 2023 12 likes •552 views

Green 3D Printing: From Berkeley to the World Jeremy Faludi, Susan Gladwin, Justin Bours, Lauren Heine Jeremy Faludi Printing Process Variety 3 images from renishaw.com, 3Dsystems.com, stratasys.com, afinia.com, typeamachines.com, engadget.com

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Green 3D Printing: From Berkeley to the World

Jeremy Faludi, Susan Gladwin, Justin Bours, Lauren Heine

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Jeremy Faludi

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SLIDE 3

Printing Process Variety

images from renishaw.com, 3Dsystems.com, stratasys.com, afinia.com, typeamachines.com, engadget.com

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3D Printing Myths vs. Facts

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Myth #1: No Transportation

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Myth #2: No Waste

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Energy is Main Impact

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Is 3D Printing Green? It Depends…

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images from renishaw.com, 3Dsystems.com, stratasys.com, afinia.com, typeamachines.com, engadget.com

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SLIDE 9

Is 3D Printing Green? It Depends…

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Utilization

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Utilization

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Utilization

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Obstructing Circular Economy

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Irreversible Materials

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Mixing Materials Inseparably

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image from mit.media.edu

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Enabling Circular Economy

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Efficient Vehicles

image from bloomberg.com

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Repair

Screen shot of thingiverse.com

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Democratize Production

image from 3dprintingindustry.com

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Align Economic Incentives

Material use = $ Complexity ≈ free

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image from mit.edu

Enable Green Materials?

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Susan Gladwin

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Biofriendly

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The hazards of Stereolithography (SLA) Resins

Photoinitiator (0.4%) Reactive Oligomers (79.55%) Reactive Monomer (19.88%) UV-blocker (0.16%) Reproductive toxicant Eye irritant Skin irritant Aquatic toxicant Skin sensitizer

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SLIDE 27

The life cycle for SLA Printing

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SLIDE 28
  • Industrial. $100,000s+

Light Industrial. $1,000s+ $100s

Now 2015 1990’s

Ubiquity of 3D Printing

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Open+ Creative Commons: code, CAD, materials recipe

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Collaborators

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Justin Bours

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Identify

Alternative Resin Materials

Evaluate

New Resin Materials

Explore

Bio-inspired Approaches

Greener Solutions Class Methods

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Three Tiers of Disruption

  • I. REPLACING THE PHOTOINITIATOR

Strategy A: Curcumin & Riboflavin

  • II. MODIFYING ACRYLATE-BASED RESINS

Strategy B: Triglycerides Strategy C: Chitosan

  • III. pH PHOTOINITIATED RESINS

Strategy D: Calcite Strategy E: Metal Ligand Complexes

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Hazard Comparisons

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https://onlinelibrary.wiley.com/doi/full/10.1111/jiec.12587

Autodesk + BCGC Collaborative Publication

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Framework Approach VS Other Analyses

Lack of life-cycle thinking Underrepresentation

  • f direct human

health impacts OUR APPROACH

ONLY ONLY

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Curated, stepwise framework development

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Defining the life cycle for SLA Printing

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Defining the life cycle for SLA Printing

Printing Process Stage Print Disposal Stage Print Use Stage Printing Process Waste Disposal Stage

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Identify criteria, metrics, methodologies

Criteria Metrics Methodology Human Health Profile CHA* QCat, C2C Physical Hazard CHA QCat, C2C Post-Processing Green Design, CHA Waste, Electricity Usage, QCat, GreenScreen Ultrafine Particles CHA, RA** QCat, C2C, Volume

  • f particles

VoC Emissions CHA, RA QCat, GreenScreen, Volume of particles

Printing Process Stage

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Human Health Profile of AM Materials Autodesk PR48 PL A Printing Process Stage

Toxicity Endpoint Categories

PR48 is significantly more hazardous than PLA

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PLA substantially outperforms Autodesk PR48*

*Comparing materials from similar technologies will likely result in closer ratings

Printing Process Printing Process Waste Disposal Print Use

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Print Disposal

1 Overall 0.5

Printing Process

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Printing Process Waste Disposal

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Print Use

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Print Disposal

2 Overall 1.75

Autodesk’s PR48 PL A

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Using framework to identify improved materials/processes

Using an acrylate resin with a bio-derived backbone Printing Process Printing Process Waste Disposal Print Use

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Print Disposal

1 Overall 0.5 1 1 2 1 1.25

Arakawa, Christopher Kenji. “A Novel Photopolymerizable Chitosan Collagen Hydrogel for Bone Tissue Engineering,” 2012. http://escholarship.org/uc/item/1wp7v2g2.pdf.

Autodesk’s PR48

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http://blogs.autodesk.com/netfabb/2015/11/18/t

  • wards-sustainable-biofriendly-materials-for-

additive-manufacturing-part-1-of-3/

Autodesk blogs on this work

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SLIDE 45

Lauren Heine

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3D Printing Roundtable

Justin Bours, Lauren Heine, Amelia Nestler, Mark Buczek and Jeremy Faludi Northwest Green Chemistry, Autodesk, Cradle to Cradle Products Innovation Institute Dartmouth College 46

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Publication Framework and Other Research

LCA

INSIGHT S INSIGHT S INSIGHT S Roundtable Discussion AM Product Design Scorecard Printer Materials Printer Design Printer Operations

Designing an AM Product Design Scorecard

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NGOs

  • Northwest Green Chemistry
  • Cradle to Cradle Products Innovation Institute
  • Ellen MacArthur Foundation
  • Green Chemistry and Commerce Council

Academia

  • Berkeley Center for Green Chemistry
  • University of California Irvine
  • Universidad de Santiago de Chile, Alysia Garmulewicz
  • Dartmouth College

Government

  • US EPA
  • WA State Department of Ecology
  • Oregon Department of Environmental Quality

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Printer/Software Manufacturers

  • Autodesk
  • XYZprinting
  • Pollen AM
  • Structo 3D

Material Manufacturers

  • Clariant
  • Covestro
  • CPS Polymers
  • Millipore-Sigma
  • NatureWorks
  • SABIC
  • ZilaWorks

AM Users

  • Lego

Consulting firms/Industry Expertise

  • Pre Sustainability Consultants

Participants in the 3D Printing Roundtable

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SLIDE 49
  • An appropriate assessment tool can support decision making for both:
  • Material selection and
  • Product design
  • Results should be simple and visual
  • There will always be tradeoffs and imperfect information,
  • Tradeoffs should be transparent
  • No one assessment tool can provide all of the answers on sustainability;

they need to be used together in a systemic way

  • Life cycle (impact) assessment
  • Chemical hazard assessment
  • Exposure assessment
  • Risk assessment
  • Circularity Assessment (Sustainable Materials Assessment)

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Participant Recommendations

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SLIDE 50

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Prototype: Printer Design Scorecard

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Greater scope–more thorough assessment

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  • Research in collaboration with OR DEQ

(proposed)

– What is extent of the use of Additive Manufacturing in Oregon? – What are key activities and materials of concern – Where are opportunities for intervention

  • Development of a Green Design and

Assessment Framework (NGC with WA DOE)

– Address each life cycle stage – Design with the end in mind – Principle-based – Consider hazard, exposure, life cycle impacts

  • Future developments of the Scorecard

–Scoping –Funding –Participant champions

Emergent Activities

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Panel Discussion Thank you! Any questions?