HP Innovation Journal Issue 12: Summer 2019 | Page 61

FINDING ENERGY EFFICIENCIES
IN MANUFACTURING
Manufacturing today consumes more than one-third of all
global energy production, produces 20% of greenhouse gas
(GHG) emissions, and is responsible for one-fourth of the
resource extraction. 6 Additive Manufacturing (AM) can
create material energy savings in the global $12T manufac-
turing sector by reducing energy consumed through the
design, manufacturing, and use of parts (e.g., the full life-
cycle). Reductions can come from leveraging AM’s ability
to produce lightweight designs and structures not possible
using traditional (subtractive) manufacturing design and
production.
Innovations in additive manufacturing (AM) such as HP
Multi Jet Fusion 3D printing technology have the potential
to save energy and cost across the full product lifecycle.
This is possible because AM can reduce part mass and
provide energy savings through product lifecycle phases
ranging from feedstock, manufacturing, transportation,
use, and maintenance. It is forecast that AM techniques
could generate global energy demand savings ranging from
5% to 27% by 2050. Look at the aerospace sector to see
how this is possible. One study has estimated that the
empty weight of an Airbus A320 could be reduced from
42,400 kg to 33,300 kg (a 21% reduction) by using lighter
AM-printed parts.
One kilogram (kg) of aircraft
weight elimination reduces aircraft
annual fuel consumption by 114 kg,
the equivalent to 300 kg of CO2.
On a fleetwide basis, full-sector
energy savings of 5% to 25% are
possible through end-to-end
design and production using AM. 7
Material savings are possible in most industrial sectors,
including automotive. 3D printers with a mature “design to
print” 3D ecosystem will make this possible, providing an
environmentally sustainable ROI to product manufacturers.
59