Implications of topology optimization on the ecological efficiency of the LPBF process

Laser Powder Bed Fusion (LPBF) offers possibilities towards a sustainable manufacturing due to high powder material recycling rates or manufacturing of lightweight and topology optimized (TO) components. In order to evaluate sustainability respectively resource consumption, Life Cycle Assessment (LCA) is employed, and a virtual model of the physical LPBF process is developed. For conclusive modeling, however, primary data of resource flows and energy consumption must be known. Especially the influence of topology optimization on the resource consumption in LPBF and on the resulting footprint of manufactured geometries is barely investigated. In the present work, TO approaches on an aerospace component are used to reduce the components volume. Two iterations of the component are built on a commercial LPBF system and primary energy data is measured. A LCA model has been developed to compare the ecological impacts of these iterations. Results indicate that by applying TO, the footprint can be reduced.